Process for Increasing Throughput of Corn for Oil Extraction

ABSTRACT

Corn oil is extracted from corn to form a corn meal. Processing the corn grain to obtain the oil, meal, and other product streams generally includes dividing the corn kernel by fractionating to create a higher oil fraction and a lower oil fraction, forming a solvent extractable structure from the higher oil fraction, and extracting the oil from the higher oil fraction. The extracted corn oil is useful for making nutritionally enhanced edible oil or cooking oil, lubricants, biodiesel, fuel, cosmetics and oil-based or oil-containing chemical products. The extracted corn meal is useful for making enhanced animal feed rations, snack food, blended food products, cosmetics, and fermentation broth additive. The lower oil fraction is useful for one or more processes such as fermentation, wet-milling, animal feed production, sweetener production, and starch production, making enhanced animal feed rations, snack food, blended food products, and cosmetics.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/564,202, filed Apr. 21, 2004 and U.S. Provisional Application No.60/628,069 filed Nov. 15, 2004, which are herein incorporated byreference.

BACKGROUND OF THE INVENTION

The present invention relates to a process for increasing the output ofextracted corn oil.

Corn, Zea mays, is grown for many reasons including its use in food andindustrial applications. Corn oil and corn meal are two of many usefulproducts derived from corn. Commercial processing plants utilizingconventional methods for extracting corn oil from conventional cornseparate the corn seed into its component parts, e.g., endosperm, germ,tip cap, and pericarp, and then extract corn oil from the corn germfraction. Corn germ produced by wet or dry milling may be processed bypressing the germ to remove the oil or by flaking the germ,pre-pressing, and extracting the oil with a solvent. In both of theseprocesses, because the germ was separated from the remainder of thekernel, many or all of the valuable components of the endosperm fractionare absent from the oil.

In contrast to the traditional wet or dry milling of the separated corngerm, other processes involve the whole corn kernel, resulting in anincrease in the oil of the components from the endosperm. U.S. Pat. Nos.6,313,328 and 6,388,110 describe a commercial-scale method forprocessing whole kernel corn grain having a total oil content of atleast about 8 wt. %, including the steps of flaking corn grain andextracting a corn oil from the flaked corn grain. The method can beeffectuated by processing the corn grain using methods and equipmenttypically used to process soybeans and other similar oilseed types. U.S.Pat. No. 6,610,867 describes a process for extracting corn oil to formcorn meal. The process generally includes the steps of cracking wholekernel corn having a total oil content of from about 3 wt. % to about 30wt. % and extracting a corn oil from the cracked corn grain. The corn isnot flaked. U.S. Pat. No. 6,648,930 discloses products comprisingextracted corn oil and corn meal obtained from whole high oil corn. U.S.Patent Publication No. 2002/0151733A1 discloses methods of manufacturingand processing corn oil and corn meal by flaking whole corn grain havinga total oil content of from about 3 wt. % to about 6 wt. % andextracting a corn oil from the flaked corn grain.

BRIEF SUMMARY OF THE INVENTION

The present invention includes a method of dividing a whole corn kernelof high oil corn comprising: fractionating a whole corn kernel of highoil corn having a range of moisture from about 8 wt. % to about 22 wt.%, and further having an endosperm component and a germ component, intoa higher oil fraction and a lower oil fraction, wherein, the higher oilfraction has an oil concentration greater than that of the corn kerneland the lower oil fraction has an oil concentration less than that ofthe corn kernel. In one embodiment, fractionating comprises contactingthe whole corn kernel with an abrasive screen to separate at least aportion of the germ component of the corn kernel from at least a portionof the remainder of the corn kernel. In one embodiment, fractionatingcomprises subjecting the whole corn kernel to a Buhler L machine, aSatake debranner, or other means for contacting the corn kernel with adevice to remove at least a portion of the germ component of the cornkernel from at least a portion of the remainder of the corn kernel. Inone embodiment, the method further comprises separating the lower oilfraction into larger and smaller pieces of lower oil fraction andfractionating the larger pieces of the lower oil fraction into a secondstage higher oil fraction and a second stage lower oil fraction.Optionally, the second stage higher oil fraction and the higher oilfraction are combined. Optionally, the second stage lower oil fractionand the lower oil fraction are combined.

Another embodiment of the present invention includes cracking the cornkernel into at least two differing sized pieces of cracked corn prior tofractionating the cracked corn. In one embodiment, cracking comprisescutting the endosperm component of the corn material into pieces ofpredominantly from about 2540 microns to about 4270 microns in size andproducing a germ component predominantly greater than about 4750 micronsin size. In another embodiment, cracking step comprises using acorrugated roller mill.

In one embodiment, a first size of cracked corn pieces comprisepredominantly small size pieces of cracked corn which comprise less thanabout 10 wt. % of the cracked corn pieces. In one embodiment, the smallsize pieces of cracked corn are less than about 1080 microns in size. Inone embodiment, a second size of cracked corn pieces comprise mediumsize pieces of cracked corn which comprise about 70 wt. % of the crackedcorn pieces. In one embodiment, the second size pieces of cracked cornare from about 2540 to 4270 microns in size. In one embodiment, a thirdsize of cracked corn pieces comprise large pieces of cracked corn whichcomprise about 20 wt. % of the cracked corn pieces. In one embodiment,the third size pieces of cracked corn predominantly are greater thanabout 4750 microns in size. In one embodiment, third size of crackedcorn pieces comprises about 30 wt. % to about 40 wt. % germ component.In another embodiment, at least three sizes of cracked corn pieces areproduced and the large size pieces of cracked corn comprise from about11 wt. % to about 22 wt. % oil and the small and medium size pieces ofcracked corn comprise about 4.5 wt. % to about 8 wt. % oil. In anotherembodiment, the large size pieces of cracked corn comprise about 16% wt.% oil.

In an alternative embodiment, a portion of the cracked corn pieces isseparated into at least two fractions according to their size. Suitableseparating techniques include size separation or gravity separation. Onesize separation technique comprises screening.

In one embodiment, the method comprises fractionating a portion of thesmall size pieces of cracked corn material into a higher oil fractionand a lower oil fraction, wherein the higher oil fraction has an oilconcentration greater than that of the small size pieces of cracked cornmaterial and the lower oil fraction has an oil concentration less thanthat of the small size pieces of cracked corn material. In oneembodiment, a portion of the smaller size pieces of cracked corn areaspirated to remove bran. In one embodiment, a portion of the largersize pieces of cracked corn are flaked or ground.

In a further embodiment, the corn kernel, the cracked corn pieces,and/or the higher oil fraction of the cracked corn pieces are temperedat a temperature and for a time sufficient to increase the differentialhardness between the germ component and the remainder of the cornkernel. In one embodiment, the corn kernel or cracked corn pieces aretempered up to a maximum of about 1% additional moisture, about 2%additional moisture, or about 3% additional moisture. In one embodiment,tempering comprises heating the corn material directly or indirectly andadding moisture to the corn material by spraying water, an aqueoussolution, and/or sparging steam.

In an alternative embodiment of the present invention, the oil isextracted from a portion of the higher oil fraction, combination cornmaterial, flaked and cracked corn, or ground and cracked corn, from afirst combination material comprising a portion of the ground crackedcorn and a portion of the higher oil fraction, from a second combinationmaterial comprising a portion of the first combination material and aportion of the flaked corn material, from a third combination materialcomprising a portion of the flaked, cracked corn and a portion of thehigher oil fraction to produce an extracted corn oil and an extractedcorn meal. One of skill in the art will appreciate that other cornmaterial, or other corn material containing oil, can also be added to aproduct produced in the present invention, and the oil extracted.

In one embodiment, a portion of the higher oil fraction, combinationmaterial, or ground, cracked corn, or first combination material isformed into a solvent-extractable structure. Methods used in forming thesolvent-extractable structure include one or more of extruding,expanding, expelling, pelleting or enzymatic treatment. Solventextraction is one method of extracting oil from a portion of thesolvent-extractable structure to produce an extracted corn oil and anextracted corn meal. Useful solvents for solvent extraction include, forexample, hydrocarbons, alkanols, alkanol-containing aqueous solutions,and supercritical carbon dioxide. Examples of such solvents include, butare not limited to C₂-C₈ hydrocarbons, C₁-C₄ alkanols, includingmethanol, ethanol and isopropanol. Mixtures of solvents may be used.Hexane(s) is a preferred solvent. In one embodiment, the solventcomprises carbon dioxide from a fermentation process.

In one embodiment, a portion of the extracted corn meal or extractedcorn oil is desolventized.

The whole high oil corn kernel comprises from at least about 3.5 wt. %,at least about 4%, at least about 4.5%, at least about 5%, at leastabout 5.5%, at least about 6%, at least about 6.5%, at least about 7%,at least about 7.5%, at least about 8%, at least about 8.5%, at leastabout 9%, at least about 9.5%, at least about 10%, at least about 10.5%,at least about 11%, at least about 11.5%, at least about 12%, at leastabout 12.5%, at least about 13%, at least about 13.5%, at least about14%, at least about 14.5%, at least about 15%, at least about 15.5%, atleast about 16%, at least about 16.5%, at least about 17%, at leastabout 17.5%, at least about 18%, at least about 18.5%, at least about19%, at least about 19.5%, at least about 20%, at least about 20.5%, atleast about 21%, at least about 21.5%, to about 22 wt. % oil on a drymatter basis. In one embodiment, the corn kernel comprises at leastabout 3.5 wt. % oil on a dry matter basis.

In one embodiment, the lower oil fraction comprises less than about 3wt. % oil on a dry matter basis. The range of moisture in the whole cornkernel of high oil corn is from about 8% to about 18%.

The invention further comprises using a portion of the lower oilfraction as a feedstock for fermentation, wet corn milling, food, petfood or other process. In another embodiment, the invention furthercomprises using a portion of the desolventized, extracted meal as afeedstock for fermentation, wet corn milling, food, pet food, or otherprocess.

In one embodiment, the invention comprises using a portion of the higheroil fraction as a feedstock for fermentation, food, pet food, or otherprocess. In an alternative embodiment, the invention comprises using aportion of removed bran as a feedstock for extraction. In anotherembodiment, the invention comprises extracting a portion of phytosterolsfrom the bran feedstock.

In another embodiment of the present invention, feed pellet quality isimproved by substituting Enhanced Meal of the present invention foryellow #2 corn. In one embodiment, the substitution of Enhanced Meal foryellow #2 corn provides for decreased energy usage at the feed mill.

Another aspect of the invention provides methods of separating wholekernel corn into a high oil fraction using a degerminator that providesa higher oil fraction wherein less than 50%, 60%, 70%, 80% or 90% of thegerm in the high oil fraction is intact. Exemplary degerminators includethe Buhler-L apparatus (Buhler GmbH, Germany), a Satake VCW debranningmachine (Satake USA, Houston, Tex.), or other apparatus wherein theincoming corn material is contacted with an abrasive device such as ascreen to remove the hull and the germ component of the corn materialfrom a portion of the remainder of the corn material (endospermcomponent). The lower oil fraction from machines using abrasive forces,such as those mentioned herein produces a lower oil fractions and highoil fractions that are useful as a fermentation feedstocks and/orstreams that can be introduced into corn wet milling processes. When thelow oil fraction and/or the higher oil fraction is used as afermentation feedstock or as a stream that is introduced into a corn wetmilling process the starting material can be any variety of whole kernelcorn, including yellow #2 dent as well as higher oil corn.

The present invention relates to products that are derived from oil andmeal extracted from corn pursuant to the process of the presentinvention, and the uses of such products, including, but not limited to,the extracted corn oil produced by any of the methods of the presentinvention, extracted corn meal (whether or not desolventized) producedby any of the methods of the present invention, an animal feedcomprising such meal, the lower oil fraction produced by any of themethods of the present invention, an animal feed comprising such loweroil fraction, and an animal feed comprising the combination of such anextracted corn meal and a lower oil fraction. In addition, the presentinvention relates to the use of such products, including the use of suchproducts in food and other products more fully described herein.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 is a schematic flow chart of one embodiment of the presentinvention.

FIG. 2 is a schematic flow chart of one embodiment of a two stagefractionation process of the present invention.

FIG. 3 is a front elevational view of a fractionating apparatus with asix-sided screen.

FIG. 4 is a cross section of a polygonal-sided screen of a fractionatingapparatus.

FIGS. 5, 5A, and 5B are schematic flow charts of alternative embodimentsof the present invention.

FIG. 6 is a schematic flow chart of an alternative embodiment of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

Botanically, a maize kernel is known as a caryopsis, a dry, one-seeded,nut-like berry in which the fruit coat and the seed are fused to form asingle grain. Mature kernels are composed of four major parts: pericarp(hull or bran), germ (embryo), endosperm, and tip cap.

The scutellum and the embryonic axis are the two major components of thegerm. The scutellum makes up about 90% of the germ and stores nutrientsmobilized during germination. During germination, the embryonic axisgrows into a seedling. The germ is characterized by its high fatty oilcontent. It is also rich in crude proteins, sugars, and ashconstituents. The scutellum contains oil-rich parenchyma cells whichhave pitted cell walls.

The endosperm contains the starch, and is lower in protein than the germand the bran. It is also low in crude fat and ash constituents. Cornendosperm includes some valuable components such as carotenoids, lutein,and zeaxanthin. Carotenoids in grains are classified into two generalgroups, the carotenes and the xanthophylls. The carotenes are importantbecause they are vitamin A precursors. Blessin et al. (Cereal Chemistry,40, 582-586 (1963)) found that over 90% of the carotenoids, of whichbeta-carotene is predominant, are located in the endosperm of yellowdent corn and less than 5% are located in the germ. Vitamin A is derivedprimarily from beta-carotene. Another group of valuable components foundin the endosperm includes the tocotrienols. Grams et al. (1970)discovered that in corn, tocotrienols were found only in the endosperm,whereas the germ contained most of the tocopherols. Tocotrienols can beextracted from plant material using various solvents. Processes forrecovering tocotrienols from plant material are described by Lane et al.in U.S. Pat. No. 5,908,940, the entire disclosure of which isincorporated by reference. Accordingly, the process described hereinprovides a nutritionally enhanced corn oil enriched with lutein,zeaxanthin, and/or beta-carotene and optionally one or more othernutritional components. Oil-based products made with corn oil obtainedby a process of the present invention described herein can containhigher levels of important nutrients than similar products made withcorn oil produced by conventional methods. The corn oil obtained by theextraction methods described herein will include the corn oil from theboth germ component and endosperm component, and may include one or moreother components extracted from the rest of the kernel. The one or moreother components can be oil from the endosperm, tocotrienols,tocopherols, carotenoids, carotenes, xanthophylls, and sterols.Tocopherols (vitamin E) and vitamin A are antioxidants and fat-solublevitamins. When included in the diet, both have demonstrated healthbenefits. Blending of oil of the present invention with other oils orsubstances to achieve an appropriate level of beta-carotene, vitamin E,and tocotrienols is deemed within the scope of the present invention. Insome embodiments, extracted corn oil prepared as described hereincomprises about 0.1 wt. % to about 0.5 wt. % of tocopherol. Oil producedin accordance with the present invention also may include approximatelya 200% to 300% increase in tocotrienol content overconventionally-produced crude corn oil. Using a method of the presentinvention, the corn is prepared and corn oil extracted, and thenanalyzed for tocotrienol content. The actual minimum and maximum valuesfor tocotrienol content will depend upon the particular high oil cornused.

Extraction of carotenes and xanthophylls and other pigments is describedin detail by Blessin (Cereal Chemistry, 39, 236-242 (1962); the entiredisclosure of which is incorporated by reference). Combinations ofsolvents, primarily ethanol and hexanes, can be used to extractcarotenes and xanthophylls from corn. Ethanol, hexanes, other solventscombinations, and ratios thereof may be used to produce oil of thepresent invention on a commercial scale.

Exemplary embodiments of the crude oil obtained according to theextraction method described herein generally possess the partialcomposition profile featured in Table 1.

Table 1

TABLE 1 Exemplary Extracted Extracted High Oil Component High Oil CornCorn (Range) FFA (%) 1.45  0.7-3.00 C16:0 11.4 10-14 C18:0 2.1 1.5-3.5C18:1, cis 33 26-50 C18:1, trans C18:2, cis 50 42-60 C18:2, trans C18:30.8 0.6-1.6 Phosphorus (ppm) 190 100-400 Total Tocopherols (%) 0.130.1-.50

Fatty acids generally found in the corn oil generally include palmitic,stearic, oleic, linoleic, and linolenic acids.

The maize kernel is covered by a water-impermeable cuticle. The pericarpis the mature ovary wall which is beneath the cuticle, and comprises allthe outer cell layers down to the seed coat. It is high innon-starch-polysaccharides, such as cellulose, pentosans, andhemicellulose. Because of its high fiber content, the pericarp is tough.The tip cap, where the kernel is joined to the cob, is a continuation ofthe pericarp, and is usually present during shelling. It contains aloose and spongy parenchyma.

Whole kernel corn seed or grain harvested from any of several differenttypes of corn plants can be used in the present invention. These typesof corn plants are, for example, hybrids, inbreds, transgenic plants,genetically modified plants, or a specific population of plants. Usefulcorn grain types include, for example, flint corn, popcorn, flour corn,dent corn, white corn, and sweet corn. As used herein, the terms “wholekernel” or “whole corn” mean a kernel that has not been separated intoits constituent parts, e.g. the hull, endosperm, tip cap, pericarp, andgerm have not been purposefully separated from each other. Purposefulseparation of one corn constituent from another does not include randomseparation that may occur during storage, handling, transport, crushing,flaking, cracking, grinding, or abrading. A purposeful separation of theconstituent part is one wherein at least 50% of one constituent, e.g.,germ, has been separated from the remaining constituents. As usedherein, the term “corn material” refers to whole corn, cracked corn,screened corn, and aspirated corn, whether or not conditioned ortempered.

Useful corn grain for the processing method of the present invention hasa total oil content from at least about 3.5 wt. % to at least about 22wt. % on a dry matter basis. The total oil content of corn grainsuitable for the present invention can be, for example, grain having anoil content at least about 3.5 wt. %, at least about 5 wt. %, at leastabout 6 wt. %, at least about 7 wt. %, at least about 8 wt. %, at leastabout 9 wt. %, at least about 11 wt. %, at least about 12 wt. %, atleast about 15 wt. %, at least about 18 wt. %, at least about 20 wt. %,at least about 22 wt. %, from about 3.5 wt. % to about 22 wt. %, fromabout 10 wt. % to about 22 wt. %, or from about 14 wt. % to about 22 wt.%, and values within those ranges.

Although the oil content can be determined at any moisture content, itis acceptable to normalize the oil content to a moisture content ofabout 15.5%.

Preferably, the corn grain used in the process of the present inventionis high oil corn. As used herein, the phrase “high oil corn” refers tocorn grain comprising at least about 6 wt. % or greater, preferably atleast about 7 wt. % or greater, and preferably at least about 8 wt. % orgreater oil. A high oil corn has an elevated level of oil as compared toconventional yellow dent corn, which has an oil content of about 3 wt. %to about 5 wt. %. High oil corn useful in making the oil and mealdescribed herein are available from Pfister Hybrid Corn Co. (El Paso,Ill.), Wyffels Hybrids Inc. (Geneseo, Ill.), Galilee Seeds Research &Development (Rosh Pina, Israel), or DuPont Specialty Grains (Johnston,Iowa). Other suitable high oil corn includes the corn populations knownas Illinois High Oil (IHO) and Alexander High Oil (Alexo), samples ofwhich are available from or through the University of Illinois MaizeGenetics Cooperation Stock Center (Urbana, Ill.). Methods for developingcorn inbreds, hybrids, transgenic species, and populations that generatecorn plants producing grain having elevated oil concentrations are knownand described in Lambert (Specialty Corn, CRC Press Inc., Boca Raton,Fla., pp. 123-145 (1994) and in U.S. Patent Publication No.2003/0182697, incorporated herein by reference.

Corn grain having an elevated total oil content is identified by any ofa number of methods known to those of ordinary skill in the art. The oilcontent of grain, including the fat content of a meal extracted from thegrain, can be determined using American Oil and Chemical SocietyOfficial Method, 5^(th) edition, March 1998, (“AOCS method Ba 3-38”).AOCS method Ba 3-38 quantifies substances that are extracted bypetroleum ether under conditions of the test. The oil content orconcentration is the weight percentage of the oil with respect to thetotal weight of the seed sample. Oil content may be normalized andreported at any desired moisture basis. Other suitable methods foridentifying high oil corn grain include using a near infrared (NIR) oildetector to select corn ears having corn kernels with elevated oillevels. Likewise, an NIR detector can also be used to select individualcorn kernels having elevated levels of corn oil. However, selectingindividual ears and/or kernels having elevated oil content may not becost effective in identifying high oil kernels suitable for processingusing methods described herein. Generally, corn seed producing cornplants that yield grain having elevated total oil concentrations isplanted and harvested using known farming methods.

Generally, the range of hardness of the commercial corn grain used inthe present invention is in the range of from about 46 to about 60 wt. %as measured by a Quaker hardness test; but corn grains having a hardnessoutside of this range may also be used. A preferred grain hardness is 55wt. %. Altering the hardness of the grain will cause changes to theoperating conditions to obtain the best results. For example, the harderthe grain, the more heat that will be used to temper the grain. Hardergrains provide better feed for cracking and screening processes.However, softer grains increase throughput characteristics at thefractionator.

Referring to FIG. 1, in one embodiment of the process of the presentinvention, incoming whole corn kernels (1) are conveyed into afractionator (2). Suitable fractionating equipment includes the Buhler-Lapparatus (Buhler GmbH, Germany), a Satake VCW debranning machine(Satake USA, Houston, Tex.), or other apparatus wherein the incomingcorn material is contacted with an abrasive device such as a screen toremove the hull and the germ component of the corn material from aportion of the remainder of the corn material (endosperm component). Asused herein, “germ component” refers to a portion of the corn materialcontaining corn germ, fractions of corn germ, components of germ, oroil-bodies. Some of the germ component and hull are removed from thecorn kernels by pushing and rubbing the kernels at and against thescreen. The removed germ component and the bran go through the screenand form a higher oil fraction (“HOF”) (3). The material left on thescreens (the endosperm component) is a lower oil fraction (“LOF”) (4),but will contain some germ component. The HOF has an oil concentrationgreater than that of the corn kernels and the LOF has an oilconcentration less than that of the corn kernels. As used herein,“endosperm component” refers to a portion of the corn materialcontaining endosperm, or components of endosperm (starch and proteinfrom outside the germ). The HOF is predominantly less than size US #18mesh sieve having a 1.00 mm opening as defined in ASTME-11specifications. Separation of HOF is enhanced by maintaining a negativepressure on the outer screen cage of the Buhler L.

A preferred embodiment includes a second fractionation step. Referringto FIG. 2, incoming whole corn kernels (1) are conveyed into afractionator (2). The resulting LOF (4) is screened using a vibratingscreening and shaking device (44), such as that manufactured by Rotex(Rotex, Inc., Cincinnati, Ohio, Model #201GP) or Buhler the “MPADPansifter”). A 6000 micron screen is preferred. Particles of the LOFsize A5-30 and larger (45) are then conveyed to a second stagefractionator (47), which in one embodiment is a duplicate of the firststage fractionater. The resulting second-stage LOF stream (48) can becombined with the stream of screened particles of the LOF less than sizeA5-30 (46) to form combined LOF (51). Similarly, the second-stage HOFstream (49) can be combined with the HOF stream (3) to form combined HOF(50).

In the following paragraphs, unless otherwise specified, where thesecond stage fractionation step is used, HOF (3) may be replaced inwhole or part by combined HOF (50) or second stage HOF stream (49). TheHOF (3) may be conditioned. Conditioning may be used when the residualoil level of the HOF exceeds about 6%. The HOF may be conditioned (5)using methods known to those of ordinary skill in the art. As usedherein, the term “conditioning” refers to a process by which the cornmaterial is heated prior to expansion to improve the plasticity of theexpandette. As used herein, an “expandette” is what is produced bysubmitting the HOF (3) or conditioned HOP (6) to an expander. Anexpandette is also referred to herein as “expanded, shaped HOF”. As usedherein, “plasticity” refers to the combination of properties of anexpandette: how well it holds together in a structure, that it containsa low amount of fines, it has a high level of structural integrity, ithas high porosity (good drainage), and it has low complexation betweenoil and starch. As used here, “fines” refers to particles that passthrough a US #18 mesh sieve having a 1.00 mm opening as defined inASTME-11 specifications. The amount of fines is determined by sifting.The amount of fines should be less than about 20 wt. % and preferably isless than about 10 wt. %. The porosity, complexation, and extractabilitycan be determined as described in Aguilera et al., “Laboratory and PilotSolvent Extraction of Extruded High-Oil Corn”, JAOCS, 63(2):239-243(1986). Structural integrity may be determined by testing in a Model 2Crown pilot extractor. Acceptable results are that the recirculationpump does not plug, drainage is acceptable to an experienced operatorand the residual oil in the meal is less than about 2.0 wt. %. Apreferred residual oil level in the meal is less than about 1.5 wt. %.Optimum quality of expandettes are produced with a moisture level ofbetween about 10% and about 14%.

Conditioning may include the addition of steam (saturated and/orsuperheated) and/or water to the corn. The conditioning temperaturesrange between about 25° C. and about 95° C. and the moisture can beincreased up to about an additional 10% of the moisture. It is preferredto use corn material which does not need to be conditioned. Oneconditioner which may be used is a Buhler homogenizer (Model DPSD,Buhler Gmbh, Germany). The HOF (3) or conditioned HOF (6) is conveyed toan expander (7) and/or pellet mill (8). The expanded and/or pelleted HOF(9) is subjected to extraction (10) to recover the extracted oil (11)and the extracted meal (14). It is preferred to expand the HOF ratherthan to pellet the HOF, as a pellet is generally not as extractable asan expandette.

A useful expander (7) is the Buhler Condex Expander DFEA-220 (BuhlerGmbH, Germany) fitted with a 30 slot 8 mm die head to form shapedexpanded HOF (9). The shaped, expanded HOF (9) is cut to desired lengthsby the expander. Steam is sparged into the expander barrel to give thecorn material the plasticity to produce the shaped, expanded HOF (9).Other expanders can be used. Those of skill in the art are familiar withadjusting the operating conditions of an expander in order to providethe requisite plasticity to the expandette. Using an expander or pelletmill provides the HOF in a solvent-extractable structure without usingflaking.

Corn oil (11) is extracted from the HOF (9) by one or more extractionsteps using any extraction method. Generally, substantially, or aboutall of the oil is extracted in a single extraction process. At leastabout 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85,90, or 95% of the oil is extracted. Useful extraction methods includesolvent extraction, continuous solvent extraction, hydraulic pressing,expeller pressing, aqueous and/or enzyme extraction. Useful solvents forsolvent extraction include, for example, hydrocarbons, alkanols,alkanol-containing aqueous solutions, and supercritical carbon dioxide.Examples of such solvents include, but are not limited to C₂-C₈hydrocarbons, C₁-C₄ alkanols, including methanol, ethanol andisopropanol. Mixtures of solvents may be used. Hexane(s) is a preferredsolvent. For example, corn oil can be extracted from the HOF (9) using ahexane-based solvent extractor. Solvent extractors can include bothpercolation and immersion type extractors. In a preferred embodiment, acontinuous solvent extraction process allows the HOF (9) to remain incontact with the solvent for at least 10 minutes, at least 30 minutes,or at least 45 minutes. The less time the HOF is in contact with thesolvent, the more economical the extraction process. Equipment used forthe extraction of oil from oilseeds, such as soybean and canola, can beused to prepare the extracted corn oil and extracted corn meal describedherein.

Materials removed from solvent-based extractors include extracted cornmeal (14) and extracted corn oil in the form of miscella (11). Amiscella is a mixture comprising extracted oil and solvent. Theextracted corn meal comprises the materials that remain after some orall of the solvent-soluble material has been extracted. The extractedcorn meal (14) also contains a quantity of solvent. Solvent is reclaimedfrom both the miscella and the extracted corn meal using methods such asrising film evaporation, or drying, and raising the temperature usingequipment such as flash tanks and/or de-solventizer/toasters (12, 15).For example, heat is applied to the extracted corn meal or miscellaunder atmospheric pressure, under elevated pressure, or under vacuum toevaporate the solvent. The evaporated solvent is then condensed in aseparate recovery system, and optionally dewatered and recycled to theextractor. Alternatively, in case of using an alkanol or its solution asan extractant, oil separation from the miscella could be done by addingwater to the miscella. Such addition results in division of the miscellainto two phases. The first is an oil phase containing only small amountsof alkanol, which could be removed by distillation. The other is anaqueous solution of the alkanol, which, if required, could bere-concentrated. In a plant containing an ethanol production operation,if ethanol is used as oil extractant, re-concentration could be combinedwith ethanol separation from the fermentation liquor.

Desolventized miscella (13) is commonly termed crude oil, which can bestored and/or undergo further processing. Crude oil can be refined toproduce a final oil product. Methods for refining crude oil to obtain afinal oil are known to those of ordinary skill in the art. Hui (1996)provides a thorough review of oils and oilseeds (Bailey's Industrial Oiland Fat Products, Fifth Ed., Vol. 2, Wiley and Sons, Inc., New York,1996). Chapter three of Hui (pp. 125-158), the disclosure of which ishereby incorporated by reference, specifically describes corn oilcomposition and processing methods. Crude oil isolated using the methodsdescribed herein is of a high quality but can be further purified asneeded using conventional oil refining methods. The refining may includebleaching and/or deodorizing the oil or mixing the oil with a causticsolution for a sufficient period of time to form a mixture andcentrifuging the mixture to separate the oil.

The LOF, which contains endosperm component, is a stream higher instarch as compared to yellow #2 corn grain. This stream can be utilizedfor many applications in the food, chemicals, and industrial productsindustries. Due to its high starch content and lower oil and fiberconcentrations as compared to yellow #2 corn, this stream is an idealfeed source for many fermentation processes, including, but not limitedto ethanol and butanol production. Other uses include using this asfeedstock material to produce carboxylic acids, amino acids, proteins,and plastics as well as cosmetics and food applications.

In the following paragraphs, one of skill in the art will appreciatethat, unless otherwise specified, where the second stage fractionationstep is used, LOF (4) may be replaced in whole or in part by combinedLOF (51) or second stage LOF stream (48), respectively.

In one embodiment, the HOF (3) is combined with other oil-containingcorn material to be extracted (e.g., corn germ) and formed into asolvent extractable structure prior to extraction. In one embodiment,expanded HOF (9) is combined with other oil-containing corn materialalready in a solvent-extractable structure as a feedstock forextraction.

In one embodiment, the LOF (4) is used as a feedstock for fermentation,corn wet milling, pet food, animal feed, food applications, and/or otherprocesses. In another embodiment, the LOF is combined with theextracted, desolventized meal (16) and used as a feedstock forfermentation, corn wet milling, pet food, animal feed, foodapplications, and/or other processes. In one aspect of the presentinvention, the extracted, desolventized meal (16) can be used as afeedstock for fermentation, corn wet milling, pet food, animal feed,food applications, and/or other processes.

Analysis of components of exemplary LOF ((4) only) samples provided thefollowing:

Run 1 Run 2 Ave DB CV Ash, % 0.62 0.62 0.62 0.75 0.0% Moisture, % 17.7117.70 17.71 0.00 0.0% Fat, % 1.34 1.42 1.38 1.68 4.1% Protein, % 6.316.27 6.29 7.64 0.4% Acid 2.20 2.10 2.15 2.61 3.3% detergent fiber “ADF”,% Neutral 5.60 5.20 5.40 6.56 5.2% detergent fiber “NDF”, % Starch, %68.42 68.79 68.61 83.36 DB = dry basis

FIG. 3 is a longitudinal section view of the fractionating apparatus (2)shown in FIG. 1. In one embodiment corn material (e.g. corn kernels)(202) are conveyed into the apparatus through a cylindrical intake pipe(204) which moves the corn material into a horizontal tunnel which hasrotating screw (206) going through the tunnel. The rotating screw haslongitudinal bars (as seen in cross section in FIG. 4 at 308) runningits length and spiral flights (208) to convey the corn material into thecylindrical mill (212) which has flat polygonal sides. Air (201) pushesdown through into the horizontal cylindrical mill. The corn material ispushed down the tunnel by the flights and are rubbed against the flatpolygonal screens which form the sides of the cylindrical mill (212).The action of the corn material against these screens abrasively removesthe HOF (3), which goes through the screens and exits the mill atconduit (216) where a pressure plate (not shown) is resiliently mounted,such as with springs, over the exit of the mill to cover the exit of themill and in part control the pressure being exerted on the corn materialbeing pushed against the slits (see 307 in FIG. 4) of the mill. The LOF(4) stays within the cylindrical mill (212) and is then conveyed by thescrew down the exit (214).

FIG. 4 shows a cross section view of the screen-sided cylindrical mill(212). The polygonal-sided cylindrical mill (300) has flat sides (302)which are screens. Rotating or turning rollers (306) are rotated by axle(304). Nips (308) revolve within the screen and rub the corn materialagainst the screen to remove the HOF (3).

In one embodiment, the screens which form polygonal sides of a cylinderhave rectangular holes or slits (307) (as opposed to round holes) havingdimensions of 1 to 3 mm by 20 to 25 mm. The corn material is pushedoutwardly from the inside of the polygonal sided cylindrical mill (212)with the corn material being pushed by cylindrical-shaped rotatingrotors (306) inside the cylindrical shaped mill. The mill does not havea reduced diameter moving from the inlet to the outlet of the mill. Thecylindrical mill (212) with slits (307) is stationary with the cornmaterial being impelled horizontally down the length of the cylinder andoutwardly from the longitudinal axis of the cylinder by the rotatingcylindrical rotors to the slitted or slotted polygonal sides of thecylinder. The fractionating is done preferably with a Buhler-L apparatuswhich has six flat polygonal sides with rectangular slits and acylindrical-shaped rotor. See, e.g., WO 04/041434.

FIG. 5 depicts an alternative embodiment of the present invention. Cornkernels (1) are conveyed to a cracking apparatus (18) prior to enteringthe fractionating apparatus (2). The corn kernels may be cracked bypassing them between two rollers with corrugated teeth spinning towardeach other spaced by a defined gap, and/or passing through a grind millwhere a rotating toothed disk spins at an adjustable distance from astationary disk. Methods for cracking corn or high oil seeds aredescribed in Watson, S. A. & P. E. Ramstad, ed. (1987, Corn: Chemistryand Technology, Chapter 11, American Association of Cereal Chemist,Inc., St. Paul, Minn.), the disclosure of which is hereby incorporatedby reference in its entirety. A “cracked” corn is a corn that hasundergone the above-described cracking process.

A preferred cracking apparatus is the Roskamp series 900 cracking millroller (Roskamp, Waterloo, Iowa) with corrugated rollers with 6 teethper inch in a round bottom v design. Other cuts can also be used,including, but not limited to, a modified Dawson cut, or a LePage cut.The roller gaps of the rollers are adjusted based upon on the quality ofthe incoming grain.

The corn kernels are cracked into at least two sizes of cracked cornpieces. Preferably, there are three sizes of cracked corn pieces: thelarge size pieces of cracked corn (19), the medium size pieces ofcracked corn (19A) and the small size pieces of cracked corn (20).Preferably, the small size pieces of the cracked corn comprise less thanabout 10 wt. % of the cracked corn pieces. The small size pieces of thecracked corn are less than about 1080 microns in size. Preferably, themedium size pieces of cracked corn (19A) comprise about 70 wt. % of thecracked corn. Preferably, the medium size pieces comprise predominantlyendosperm component. As used herein, “predominantly” refers to about 90%or greater. Preferably, the medium size pieces range in size from about2540 microns to about 4270 microns. The large size pieces of crackedcorn comprise about 20 wt. % of the cracked corn. Preferably, the largesize pieces of cracked corn (19) comprise about 30 wt. % to 40 wt. %germ component. Preferably, the large size pieces of the cracked cornare greater than about US #4 mesh screen in size (4750 microns)

In one embodiment, the large, medium, and small size pieces of crackedcorn are fed into the fractionating apparatus (2) and are subjected tothe remainder of the process described above in connection with FIGS. 1,3, and 4.

In any of the embodiments described above, and as depicted in FIGS. 5Aand 5B, the corn kernels or the pieces of cracked corn are optionallytempered (21) prior to either the cracking or fractionating steps.Tempering refers to heating the corn material directly or indirectlyand/or adding moisture to the corn material. Tempering is a means touniformly distribute the added moisture and/or heat through the cornmaterial. The tempering adds up a maximum of about 1%, 2%, or 3%additional moisture to the corn material. The tempering is done toincrease the differential hardness between the germ component and theremainder of the corn material. A preferred method of tempering isheating the corn indirectly.

Any tempering method known in the art is acceptable, including, but notlimited to spraying water or sparging steam. A preferred method oftempering is to use a stacked cooker or rotary steamed tube heater.Alternatively, a steam jacket mixer may be used. In general, the corn istempered in an appropriate amount of water for any suitable length oftime, such as at least about 15 seconds, 30 seconds, 45 seconds, 1minute, and increasing in about 15 second increments up to about atleast 30 minutes. A preferred time for tempering, if tempering is used,is about 2 minutes.

An alternative embodiment of the present invention is depicted in FIG.6. Corn kernels (1) are conveyed into a cracking apparatus (18) asdescribed above. After cracking, the large size pieces of cracked corn(19) and medium size pieces of cracked corn (19A) are separated from thesmall size pieces of cracked corn (20), such as by screening (24). Onescreen which can be used in the process of the present invention is aRotex screen with a 4 mesh mill grade with 5.46 mm holes (Rotex, Inc.,Cincinnati, Ohio, Model #201GP). Other methods of separation include,but are not limited to, other methods of size separation or gravityseparation known to those skilled in the art, such as, but not limitedto, aspiration and cyclonic separation.

The medium and large size pieces of cracked corn (25) are retained bythe screen (24). The retained medium and large size pieces of crackedcorn are ground in a mill (27) or flaked in a flaker (29). A useful mill(27) is the Fitzmill comminuter (Fitzpatrick Company, Elmhurst, Ill.)fitted with a ¼ inch screen. Useful commercial-scale oilseed flakers(29) can be obtained from French Oil Mill Machinery Company, Piqua,Ohio; Roskamp Champion, Waterloo, Iowa; Buhler AG, Germany;Bauermeister, Inc., Memphis Term.; Consolidated Process MachineryRoskamp Company, on the world wide web at http://www.cpmroskamp.com, andCrown Iron Works, Minneapolis, Minn.

For high oil corn, preferably, the large size pieces of cracked corn(19) comprise from about 11 wt. % to about 22 wt. % oil. For high oilcorn, preferably the medium and small size pieces of cracked corn (19A,20) comprise from about 4.5 wt. % to about 8 wt. % oil.

After being ground in the mill, the ground cracked corn (28) is added tothe stream being fed to the expander (7) or pellet mill (8). After beingflaked, the flaked cracked corn (30) is added to the stream exiting theexpander (7) or pellet mill (8).

Optionally, the small size screened pieces of cracked corn (26) may beaspirated (31) to remove fines (bran) (32). In one embodiment, the branis added to the feed to the extractor. In one embodiment, the bran isextracted separately from other corn components. In one embodiment, thebran is used as a feedstock from which to extract one or more componentsof the bran, e.g. phytosterols. In one embodiment, the bran is used asfermentation feedstock. In yet another embodiment, the bran is used in acattle feed. In an alternative embodiment, the aspiration of the bran isnot performed until after the fractionation step. In this embodiment,the HOF (3) is aspirated to remove the bran.

In either aspiration embodiment, a separate bran (fiber) stream results.This stream contains elevated levels of pericarp carbohydrates ascompared to yellow #2 corn. The sugars associated with the fiber orpericarp are typically pentoses, which are 5 carbon sugars such asArabinose and Xylose. These carbohydrates have many uses in the food,industrial chemicals, and fuels markets. Because this stream has anelevated concentration of these key sugars, this stream can be used as afeedstock material to separate the carbohydrate sugars of interest. Inaddition, this stream can be feed directly into an ethanol fermentationprocess to utilize the sugars to produce ethanol. The bran (fiber)stream also contains valuable components such as phytosterols.

The HOF without the bran is a higher oil fraction without (or with less)fiber stream. This stream contains elevated oil and proteinconcentrations compared to yellow #2 corn grain and is a potential feedsource for industrial applications and has unique food uses. Due to itshigher protein levels, this stream can be a good feed source for water,aqueous solution, salt, pH, membrane, and/or alcohol protein extraction.This can lead to a protein concentrate for use in the food andindustrial chemicals industry. Additionally this stream can be furtherprocessed via extraction with a solvent and/or the use of water andultrasound for protein(s), amino acids, oil or novel compounds such asnutraceuticals and carotenoids. Ethanol or an ethanol solution is asuitable extractant, according to an exemplary embodiment. According toa preferred embodiment, the ethanol is produced by fermenting a kernelfraction. Extracted components could be separated from the extractformed in the extraction, e.g. by distillation of the solvent. Suchdistillation is combined with distillation in an ethanol production partof the plant. The HOF with the bran can be used as an animal feed sourceor as a food additive.

The small size screened pieces of cracked corn (26) and/or screened andaspirated small size pieces of cracked corn (33) are fed to thefractionator (2), which separates them into a higher oil crackedfraction (35) and a lower oil cracked fraction (34). In one embodiment,the lower oil cracked fraction is used as a feedstock for fermentation,corn wet milling, pet food, animal feed, food applications, and/or otherprocesses. In one embodiment, the lower oil cracked fraction is combinedwith extracted corn meal (16). The combination may be used as afeedstock for fermentation, corn wet milling, pet food, animal feed,food applications, and/or other processes.

The higher oil cracked fraction (35) is optionally conditioned (5) andthen conveyed to the expander (7) or pellet mill (8). Oil is thenextracted (10) from the expanded cracked higher oil fraction (39), aloneor in combination with the flaked cracked corn (30) and/or the groundcracked corn (28).

What remains after extraction of the expanded HOF (9), the expanded,cracked HOF (39), the flaked cracked corn (30), and the ground crackedcorn (28) is an extracted corn meal—a protein stream higher than yellow#2 corn. Because this stream contains very little oil, it can be used toproduce protein concentrates as well as protein isolates via an alcoholand/or water extraction process. Additional uses for this stream includeproduction of plastic pre-cursors from the proteins associated with thisstream for amino acids or novel compound separation as well as otheruses described herein.

Analysis of components of exemplary extracted HOF samples from high oilcorn provided the following:

Run 1 Run 2 Ave CV Ash, % 2.66 2.68 2.67 0.5% Moisture, % 8.71 8.66 8.690.4% Fat, % 2.18 2.23 2.21 1.6% Protein, % 11.35 11.29 11.32 0.4% ADF, %4.30 4.50 4.40 3.2% NDF, % 14.60 14.90 14.75 1.4%

In one embodiment, one or more of the HOF (3), expanded HOF (9), thehigher oil cracked fraction (35), the expanded/pelleted higher oilcracked fraction (39), as such, or after extraction, are used asfermentation feedstock.

U.S. Pat. No. 6,313,328 describes commercial-scale methods and equipmentas sufficient for extracting corn oil from at least about 1 ton of cornper day. In some embodiments, the capacity of commercial-scaleoperations ranges from about 100 tons of corn per day to about 3000 tonsof corn per day, or the capacity ranges from about 700 tons of corn perday to about 1700 tons of corn per day. Commercial-scale operations thatprocess greater than about 3000 tons of corn per day are alsosufficient. In contrast, the process of the present invention allows forprocessing of up to 10,000 tons daily.

The extracted corn oil and/or extracted corn meal and/or LOF of thepresent invention may be combined with a variety of other ingredients.The specific ingredients included in a product will be determinedaccording to the ultimate use of the product. Exemplary products includeanimal feed, raw material for chemical modification, biodegradableplastic, blended food product, edible oil, cooking oil, lubricant,biodiesel, snack food, cosmetics, and fermentation process raw material.Products incorporating the meal described herein also include completeor partially complete swine, poultry, and cattle feeds, pet foods, andhuman food products such as extruded snack foods, breads, as a foodbinding agent, aquaculture feeds, fermentable mixtures, foodsupplements, sport drinks, nutritional food bars, multi-vitaminsupplements, diet drinks, and cereal foods.

When making oil-based products according to the present invention, thoseproducts can include conventional corn oil, soy oil, canola oil, oliveoil, palm oil, sunflower oil, safflower oil, antioxidant, flavoring,hydrogenated oil, partially hydrogenated oil, and/or animal fat. Bymixing the corn oil herein with one or more other oils, blended oilproducts are made. The corn oil-based products can also includematerials such as food additives, salt, fat, food colors, β-carotene,annatto extract, curcumin or tumeric, β-apo-8′-carotenal and methyl andethyl esters thereof, natural or synthetic flavors, antioxidants, propylgallate, butylated hydroxytoluene, butylated hydroxyanisole, natural orsynthetic tocopherols, ascorbyl palmitate, ascorbyl stearate, dilaurylthiodipropionate, antioxidant synergists, citric acid, sodium citrate,isopropyl citrate, phosphoric acid, monoglyceride citrate, anti-foamingagent, dimethyl polysiloxane, crystallization inhibitor, oxystearin,amino acids, vitamin, minerals, carbohydrates, sugars, herbs, spices,acidity regulators, firming agents, enzyme preparations, flour treatmentagents, viscosity control agents, enzymes, lipids, and/or vegetable oranimal protein. Additionally, these edible products can be enhanced orenriched with protein supplements containing utilizable protein. Anexemplary food product such as a breakfast cereal could includeingredients such as meal of the present invention, wheat and oat flour,sugar, salt, corn syrup, milled corn, dried fruit, vitamin C, Bvitamins, folic acid, baking soda, and flavorings. Other exemplaryoil-based products that can comprise the oil prepared herein includefood oil, cooking oil, edible oil and blended oil.

The crude oil prepared according to the methods described herein can besubsequently partially or completely hydrogenated. Suitable methods forpartially or completely hydrogenating oil are described in D. R.Erickson, Practical Handbook of Soybean Processing Utilization (1995,AOCS Press), the entire disclosure of which is hereby incorporated byreference.

The extracted corn oil can be used as a raw material for chemicalmodification, a component of biodegradable plastic, a component of ablended food product, a component of an edible oil or cooking oil,lubricant or a component thereof, biodiesel or a component thereof, acomponent of a snack food, a fermentation process raw material, or acomponent of cosmetics. When making blended oils with the extracted oil,the blending can be done before, during, or after the extractionprocess.

Biodiesel can be produced using the extracted corn oil of the presentinvention. Biodiesel is a general term used for a variety of ester-basedoxygenated fuels. Biodiesel produced today is a mixture of fatty acidmethyl esters produced by methylating refined vegetable oil. Refined oilis preferable to crude oil or spent fryer oil due primarily to thequality of the glycerol by-product. The main drawbacks with previousbiodiesel products and related vegetable oil lubricants are lowtemperature properties and reactivity toward oxidation andpolymerization. A preferred biodiesel product comprises a low cloudpoint, reduced stearic and polyunsaturated fatty acid content, and higholeic acid content. Pour point correlates with low temperatureproperties and is influenced by the saturated fatty acid content of theoil. Polyunsaturated fatty acids are more susceptible to oxidation andpolymerization reactions.

Extracted corn oil (“ECO”) produced by the process of the presentinvention exhibits improved cloud point performance over soy, whileexhibiting similar chemical stability.

Extracted corn oil produced by the present invention can be furtherprocessed to form lubricants such as by published procedures practicedcurrently in the industry (see, e.g., U.S. Pat. No. 6,174,501).

One aspect of the present invention provides a nutritious animal feedcomprising the extracted corn meal and/or LOF produced by the presentinvention. The animal feed can comprise other nutritious products suchas vitamins, minerals, high oil seed-derived meal, meat and bone meal,salt, amino acids, feather meal, fat, oil-seed meal, corn, sorghum,wheat by-product, wheat-milled by-product, barley, tapioca, corn glutenmeal, corn gluten feed, bakery by-products, full fat rice bran, ricehulls, and many others used in the art of feed supplementation. Theanimal feed composition can be tailored for particular uses such as forpoultry feed, poultry layer feed, swine feed, cattle feed, equine feed,aquaculture feed, pet food, and can be tailored to animal growth phases.Particular embodiments of the animal feed include growing broiler feed,swine finishing feed, and poultry layer finishing feed. Feed productscan be made with the extracted corn meal that will have a higherrelative percentage of protein and lower relative percentage of oil thansimilar products made with conventional corn.

Another aspect of the present invention provides a corn oil-basedproduct comprising corn oil obtained by extraction of at least some ofthe endosperm component and some of the germ component of high oil corn.The corn oil-based product can comprise other components such asvinegar, spices, vitamins, salt, hydrogen (for forming hydrogenatedproducts), and water. The corn oil used in the products of the presentinvention will generally contain a higher proportion of β-carotene,xanthophylls, or tocotrienol than similar products made with corn oilextracted from conventional corn employing conventional methods. Thiscorn oil, from the process of the present invention, is generallyproduced by exposing both the endosperm component and the germ componentto extraction. Therefore, the solvent-extractable nutrients present fromthe endosperm component are extracted into the corn oil that has beenextracted from both endosperm and germ components. Products that can bemade with such oil include, but are not limited to, salad dressings,cooking oils, margarines, spray-coated food or feed products, breads,crackers, snack foods, lubricants, and fuels.

Another aspect of the present invention provides a method of usingextracted corn meal and/or a lower oil fraction in an animal feed rationcomprising the step of: 1) providing an extracted corn meal and/or loweroil fraction prepared by the present invention; and 2) including theextracted corn meal and/or lower oil fraction in an animal feed ration.It will be appreciated by those skilled in the art that the preferredratio of extracted corn meal and LOF in a product will approximate theamount of each in the corn kernel, less the oil.

Another aspect of the present invention provides a method of using anextracted corn oil in a food product comprising the steps of: 1)providing an extracted corn oil obtained by a method of the presentinvention; and 2) including the extracted corn oil in a food product.

Another aspect of the present invention provides a method of usingextracted corn oil as a feedstock in an oil refining process. The methodcomprises the steps of: 1) providing an extracted crude corn oilobtained by a method of the present invention; and 2) including theextracted crude corn oil in a raw material stream of an oil refiningprocess.

Another aspect of the present invention provides a method of usingextracted corn oil from a process of the present invention as aningredient in cosmetic applications. The method comprises the stepsof: 1) providing an extracted crude corn oil obtained by a process ofthe present invention; and 2) including the extracted crude corn oil ina cosmetic product. These types of cosmetics include but are not limitedto lipstick and eye liner. Another aspect of the present inventionprovides the use of an extracted corn meal and/or lower oil fraction inan animal feed or human food, wherein the extracted corn meal isobtained by a process of the present invention. Yet another aspect ofthe present invention provides the use of a corn oil in an animal feedor human food, wherein the corn oil is obtained by a process of thepresent invention.

Corn oil or corn meal quality is determined by evaluating one or morequality parameters such as the oil yield, phosphorus content, free fattyacid percentage, the neutral starch percentage, protein content, andmoisture content. Any method can be used to calculate one or more of thequality parameters for evaluating the oil or meal quality.

The lower oil fraction (4) and the extracted corn meal (16) can beprovided as a loose product or a pelleted product, optionally incombination with other components. For example, a pelleted product couldinclude the extracted corn meal (by itself or in combination with othercomponents) that has been pelleted and subsequently coated with zeinprotein. The corn meal can be included in blended meal products whichcan be provided in loose or pelleted form. Meal produced from theprocesses described herein is used to produce feed products. Blendedmeals may comprise the following ingredients in the approximate amounts:0.5-12% fat, 5-45% moisture, 5-60% protein, 2-4% crude fiber, and 40-80%carbohydrates.

Feed products containing predominantly corn meal produced by extractionrequire less supplementation with protein from other sources such assoybeans than feed products containing predominantly normal corn grain.The meal, by virtue of the composition arising from the processingmethod, offers feed manufacturers flexibility to produce feeds thatcould otherwise not be made. Animal feed rations having unique physicalproperties such as bulk density, texture, pelletability, and moistureholding capacity and/or unique nutritional properties are created byincluding the extracted corn meal of the present invention as acomponent of said rations. The extracted corn meal isolated usingmethods as described herein can, on its own, be a low-fat corn meal.Alternatively, it can be used in combination with the lower oil fractionproduced by the present invention, and/or other corn meals ornutritional components to make feed rations and food products. Theextracted corn meal and/or lower oil fraction can also be combined withmeals made from crops such as soybeans, canola, sunflower, oilseed rape,cotton, and other crops. The extracted corn meal and/or lower oilfraction can also be made from genetically modified corn and/or combinedwith meals made from transgenic oilseed grains to form an enhanced mealor enhanced product.

The feed rations prepared with the extracted corn meal and/or lower oilfraction will generally meet the dietary and quality standards set forthin the CODEX ALIMENTARIUS or by the National Research Council. The cornmeal of the present invention will generally comprise the components inthe approximate amounts indicated in Table 2 below.

Table 2

TABLE 2 Sample A Sample B Sample C Component Amount (%) Amount (%)Amount (%) Moisture  5-45  5-25  5-45 Starch 40-70 40-80 40-70 Protein 8-20  7-20  8-20 Fat (Oil) 0.75-6   0.75-6.0  0.75-12   Crude Fiber 2-42-4 Ash 1.5-3   0.5-2.0 Fructose 0.15-0.3  Glucose 0.2-0.5 Sucrose1.5-2.5 Lysine 0.15-2.0  Tryptophan 0.03-2.0 

The corn meals above may also further comprise unspecified amounts ofthe components for which no amounts have been indicated. In oneembodiment, the extracted corn meal comprises the components in theapproximate amounts: about 0.5 to 12 wt. % fat, 5-45% moisture, 7-20%protein, 4-11% crude fiber, and 40-80% carbohydrates.

The lower oil fraction will generally comprise these components in theseapproximate amounts: moisture 5-25%, oil 1-3.5%, protein 9-12%, starch40-80%, fiber 2-6%, and ash 0.5 to 2%. The lower oil fraction may alsofurther comprise other components.

Varying levels of nutrients are required by different animals dependingon species, age, and breed. Feed rations comprising different levels ofnutrients are made by subjecting the high oil corn to different degreesof extraction, i.e., more oil is removed from the corn by subjecting itto extraction to a greater degree. Therefore, feed rations comprisingthe extracted corn meal of the present invention can be made to includedifferent amounts of fat, protein, and carbohydrates by controlling theextent to which the high oil corn is extracted. Table 3 details theamounts in which the indicated ingredients are present in animal feedrations comprising the extracted corn meal, the specific inclusion rangebeing indicative of exemplary rations in which extracted corn meal is amain ingredient and the general inclusion range being indicative ofrations in which one or more other ingredients, for example,carbohydrate-based energy sources such as sorghum, wheat, and/or othercereal grains or their by-products, or other non-cereal grainingredients, may be included.

Table 3

TABLE 3 General Exemplary Ingredient Inclusion Range Inclusion RangeCorn meal described herein 2-95% 50-90% Oilseed Meal¹ 3-35% 10-30% Meatand Bone Meal 0-12% 0-7% Feather Meal 0-6%  0-4% Fat 0-10% 1-6% Salt0.1-0.5%  0.1-0.5% Lysine  0-0.4%   0-0.4% Methionine  0-0.3%   0-0.3%Nutrient Premix 0.01-1.0%  0.01-1.0%  ¹Oilseed meal can consist of, butis not limited to, soy, sunflower, canola, cottonseed, and otherplant-based meals, which themselves may or may not have been subjectedto an oil extraction process.

Meat and bone meal is obtained from suppliers such as DarlingInternational, Inc. (Irving, Tex.). Oilseed meal is obtained fromsuppliers such as Cargill Oilseeds (Cedar Rapids, Iowa). Feather meal isobtained from suppliers such as Agri Trading Corp., (Hetchinson, Minn.).Amino acids are obtained from suppliers such as DuCoa, (Highland, Ill.).

Feed rations are made by mixing various materials such as grains, seedmeals, vitamins, and/or purified amino acids together to form acomposite material that meets dietary requirements for protein, energy,fat, vitamins, minerals, and other nutrients. The mixing process caninclude grinding and blending the components to produce a relativelyhomogeneous mixture of nutrients. Physical properties of the feed rawmaterials and of the compounded feed affect the nutritional quality,storability, and overall value of the products. Suitable processes formanufacturing feed rations are disclosed in Feed ManufacturingTechnology IV (1994, American Feed Industry Association) andincorporated herein in its entirety.

As discussed herein, specific oil levels can be achieved in theextracted meal by altering processing conditions. The protein, aminoacid, and oil levels of the present extracted meal cannot be achieved insteam-flaked normal corn, and steam-flaked high oil corn may have toomuch oil, which could adversely affect ruminant animal health.

Many types of animal feed rations can be developed using extracted cornmeal of the present type. Types of animal feed rations using extractedcorn meal are described in U.S. Pat. No. 6,648,930 at col 15,incorporated herein by reference. Human food can also be developed usingextracted corn meal of the present type.

Combined LOF and extracted corn meal of the present invention can beused as an ingredient in aquaculture feed products.

One advantage of combined LOF and extracted corn meal over corndry-milled corn products is the improved protein content and quality,since the oil has been substantially removed from the kernel resultingin a meal product in which the protein has been concentrated. Thisproduct may be used in poultry feed. Because the meal is obtained fromall portions of the kernel, including the embryo, the proteins aregenerally of higher quality and quantity than would be found inextracted corn grits.

Combined extracted corn meal and lower oil fractions produced by themethod of the present invention are also useful for fermentation-basedproduction of compounds, such as, for example, butanol, ethanol, lacticacid, citric acid, and vitamins. Solvent extracted corn meal and/or thelower oil fraction can be hydrolyzed to provide soluble sugars. Themeal/lower oil fraction serves as a carbon and nitrogen source forbacterial, fungal, or yeast cultures. Biotin and other vitamins can beproduced through the cultivation of microorganisms. Organisms caninclude Pseudomonas mutabilis (ATCC 31014), Corynebacteriumprimorioxydans (ATCC 31015), Arthrobacter species, Gibberella species,Penicillium species, or combinations thereof.

Nutrients used in the cultivation of these and other microorganismsinclude, for example, starch, glucose, alcohols, ketones, and as anitrogen source, peptone, corn steep liquor, soybean powder, ammoniumchloride, ammonium sulfate, ammonium nitrate, extracted corn meal, orurea. Various salts and trace elements may also be included in media forthe culture of microorganisms. The pH of the culture medium is about 4to about 9, preferably about 6 to about 8, and most preferably about 7for bacterial species. The pH is about 5 to about 7 for mold or yeast.During cultivation, temperatures are kept between 10° C. to 100° C.,preferably between 20° C. to 80° C., more preferably between about 20°C. to 40° C., and most preferably about 25° C.

Biotin production is described in U.S. Pat. No. 3,859,167, incorporatedherein by reference.Cis-tetrahydro-2-oxo-4-n-pentyl-thieno[3,4-d]imidazoline is added to aculture medium containing solvent extracted corn meal and otherappropriate identified ingredients in combination with a microbialspecies capable of forming biotin. In general, the microorganism iscultivated for 1 to 10 days, preferably 1 to 8 days, and more preferably2 to 7 days, after which time biotin is separated and purified. In oneembodiment, to purify biotin, cells are removed from the culture medium,the filtrate is absorbed on activated charcoal, and purified with an ionexchange column. Alternative methods of purification are also used suchas crystallization by adjusting the pH of the biotin-contained solutionto near its isoelectric point.

The extracted corn meal and/or the lower oil fraction, or a combinationthereof produced by the present invention can also be further processedto produce biodegradable materials. For instance, the meal or lower oilfraction of the present invention may be incorporated as athermoplasticising agent. The meal or lower oil fraction of the presentinvention may be included in the methods described in U.S. Pat. No.5,320,669, which is incorporated herein by reference. The thermoplasticmaterial is prepared using solvent extracted corn meal, or a lower oilfraction as obtained from the process described herein. In oneembodiment, the biodegradable thermoplastic composition prepared usingthe meal or lower oil fraction of the present invention is treated withan organic solvent, and optionally a cross-linking agent, to linktogether the starch and protein of the extracted corn grain. Thecross-linking agent referred to herein may be any compound capable oflinking the starch and the protein, such as, for example, an aldehyde,an acid anhydride, or an epoxide. The compositions so formed using themeal and/or lower oil fraction of the present invention can be used tomake extruded or molded articles that are biodegradable,water-resistant, and/or have a high level of physical strength. Paperproducts may also comprise extracted corn meal produced by the presentinvention, a lower oil fraction produced by the present invention, or acombination thereof.

Blended products comprising the extracted corn meal and one or moreother oilseed meals are made by one combining the extracted corn mealwith extracted or non-extracted other oilseed meal to form a blendedmeal. At any time during these processes, additional components can beadded to the blended meals to form a blended product.

The extracted corn meal can also be used in foodstuffs such as snackfood, chips, food binding agents, food supplements, nutritional foodbars, multivitamin-supplements, blended food products, breads,fermentation feedstock, breakfast cereals, thickened food products suchcanned fruit fillings, puffed or extruded foods, and porridge.

When used in edible products for humans or animals, the extracted cornmeal and/or lower oil fraction can be combined with other componentssuch as other meal, other oilseed meal, grain, other corn, sorghum,wheat, wheat milled byproducts, barley, tapioca, corn gluten meal, corngluten feed, bakery byproduct, full fat rice bran, and rice hull.

The extracted corn meal and/or lower oil fraction can also be used as araw material for production of corn protein isolates, for fermentation,for further chemical processing, in addition enzymes, such as amylasesand proteases, can be added to the meal to help facilitate the breakdownof starch and proteins.

The extracted corn meal is optionally subjected to conventional methodsof separating the starch and protein components. Such methods include,for example, dry milling, wet milling, high pressure pumping, orcryogenic processes. These and other suitable processes are disclosed inWatson, S. A. & P. E. Ramstad, ed. (1987, Corn: Chemistry andTechnology, Ch. 11 and 12, American Association of Cereal Chemist, Inc.,St. Paul, Minn.), the disclosure of which is hereby incorporated byreference. Due to the prior removal of oil from the corn meal, thestarch, and protein components of the extracted corn meal are separatedfrom other components more easily than they would be if the corn oilwere not extracted.

Several important quality parameters for the extracted meal and loweroil fraction include the fat, starch, protein, and moisture content.Methods for evaluating quality parameters of oilseed meals are disclosedin the AOCS methods, the relevant disclosure of which is herebyincorporated by reference. These methods can also be applied to theextracted corn meal and lower oil fraction prepared as described herein.

Starting with a single corn type (e.g., 12 wt. % oil and 9 wt. %protein), more than one corn meal type can be made to meet certainnutritional requirements. The significance of this flexibility relatesto the nutrient density within feed products and to dietary requirementsof animals. One significant advantage of the use of this type of highoil corn and extraction process is that an extracted corn meal can bemade to have a specific oil level depending on the extent of oilextraction. Once the oil is removed, the remaining corn meal has anutrient density for protein, amino acids, and other nutrients notremoved by the process, greater or different than normal corn grain andgreater than that of the starting corn, e.g., 12 wt. % oil, 9 wt. %protein.

Corn meals derived using different methods or isolated at differenttimes are compared by normalizing the meals to a common moisturecontent. The moisture content of an oilseed protein concentrate, such asa corn meal or whole corn, is determined using AOCS method Ba 2b-82. Thecrude fiber content of corn meal is determined using AOCS method Ba6-84. AOCS method Ba 6-84 is useful for grains, meals, flours, feeds,and all fiber bearing material from which the fat can be extractedleaving a workable residue. Crude protein content of corn meal isdetermined using AOCS method Ba 4e-93. The starch content of corn mealis determined using AOCS method Ba 4e-93. The starch content of cornmeal is determined using the Standard Analytical Methods of the MemberCompanies of the Corn Refiners Association Incorporated, 2d Edition,Apr. 15, 1986, method A-20 (“Corn Refiner's method A-20”).

The extracted corn meal prepared as described herein advantageously canbe made to contain specific levels of oil and, in particular, specificratios of oil to protein, of oil to carbohydrate, or of oil to proteinto carbohydrate. For example, normal corn with 8 wt. % protein and 4 wt.% oil has a protein:oil ratio of 2.0, and high oil corn with 9 wt. %protein and 12 wt. % oil has a protein:oil ratio of 0.75. Meal producedby extraction to have 10.5 wt. % protein and 1.5 wt. % oil has aprotein:oil ratio of 7.0. This higher ratio makes this meal type andproducts made from it desirable for certain applications, one examplebeing a swine-finishing ration.

It is to be understood that the analytical methods provided herein areillustrative examples of useful methods for computing various qualityparameters for the oils and meals described herein. Other suitablemethods are known and may be used to compute the quality parametersdisclosed and claimed herein.

The following examples are included to demonstrate specific embodimentsof the present invention. It should be appreciated by those of skill inthe art that the techniques disclosed in the examples which followrepresent techniques discovered by the inventors to function well in thepractice of the present invention, and thus can be considered toconstitute exemplary modes for its practice. However, those of skill inthe art should, in light of the present disclosure, appreciate that manychanges can be made in the specific embodiments which are disclosed andstill obtain a like or similar result without departing from the spiritand scope of the present invention.

EXAMPLE 1

U.S. Pat. Nos. 6,313,328 and 6,388,110 describe a commercial-scalemethod for processing whole kernel corn grain having a total oil contentof at least about 8 wt. %, including the steps of flaking corn grain andextracting a corn oil from the flaked corn grain. U.S. Pat. No.6,610,867 describes a process for extracting corn oil to form corn meal.The process generally includes the steps of cracking whole kernel cornhaving a total oil content of from about 3 wt. % to about 30 wt. % andextracting a corn oil from the cracked corn grain. (Flaking is not usedin this process). All components of the whole kernel (in whatever form)are subjected to the extraction step, including those components withlower oil. By contrast, in the present process, the fractionationproduces a high oil fraction and a low oil fraction. The lower oilfraction bypasses the extraction process and can go directly to feed orother uses. Only the higher oil fraction is prepared for extraction andextracted. This process doubles the plant throughput with a very minimalinvestment.

EXAMPLE 2

High oil corn grain 1 (LH310 (inbred, Holdens Foundation Seeds)×HOI 001,see U.S. Patent Publication Nos. 2003/018269 and 2003/0172416,incorporated herein by reference) and high oil corn grain 2 (Top CrossBlend seed corn, purchased Spring 2003, grain harvested Fall, 2003,Indiana) from storage was metered in to steam jacketed paddle mixer witha retention time of about 7 minutes. The corn was heat tempered at 90°F. The tempered corn was then conveyed to a Buhler-L apparatus, (BuhlerGmbH, Germany) where the hull and softer tissue was abraded to becomethe lower oil fraction (“LOF”) and separated from the higher oilfraction (“HOF”). The results of the analysis of the grain, the HOF andthe LOF are displayed in Table 4.

Table 4

TABLE 4 Moisture Oil Split (wt. %) Grain 1 12% 8.6% HOF 1 14.5% 52% LOF1 2.3% 48% Grain 2 16% 6.7% HOF 2 13.5% 43% LOF 2 1.7% 57%

These results indicate that the oil level in over half of the cornmaterial is reduced to less than 2.5 wt. % of the LOF, allowing thisfraction to bypass the expensive extraction step.

EXAMPLE 3

High oil corn grain 1 from Example 2 was tempered as in Example 1 priorto being fed to a Roskamp series 900 cracking mill roller (Roskamp,Waterloo, Iowa). The rollers were corrugated with 6 teeth per inch in around bottom v design. The top roller gap was set at 2.5 mm and thebottom roller gap was set at 2.5 mm. The cracked tempered corn materialwas then aspirated to remove the bran. The cracked tempered de-brannedcorn material was then conveyed to the Buhler-L apparatus described inExample 1 for fractionation. The results of the analysis of the grain,the bran, the HOF and the LOF are displayed in Table 5.

Table 5

TABLE 5 Moisture Oil Split (wt. %) Grain 12% 8.6% Bran 8.9% 13% HOF20.5% 34% LOF 3.5% 53%

EXAMPLE 4

High oil corn grain 1 from Example 2 is fed to the Roskamp crackingroller mill with the settings described in Example 3 without beingtempered. From the roller mill, the cracked corn material is conveyedfor fractionation to the Buhler-L apparatus described in Example 2. Thisresults in lower throughput capacity and lower oil level in the HOF thanin Example 3.

EXAMPLE 5

High oil corn grain 1 from Example 1 was fed to the Roskamp crackingroller mill described in Example 3 but with the top roller gap set at 3mm and the bottom roller gap set at 2.5 mm. The resulting particle sizedistribution was 20% greater than 4 mesh (large size pieces) (19), 75%between 4 mesh and 12 mesh (medium size pieces) (19A), and 5% less than12 mesh (small size pieces) (20). The cracked corn pieces were thenscreened on a Rotex screener (Rotex, Inc., Cincinnati, Ohio, Model#201GP) with a 4 mesh mill grade screen with 5.46 mm holes. The piecesthat were retained on top of the screen were collected. The materialwhich passed through the Rotex screener was conveyed to the Buhler-Lapparatus described in Example 1 for fractionation. The results of theanalysis of the grain, the cracked material which did not pass throughthe Rotex screener, the HOF and the LOF are displayed in Table 6. Thelarge size particles were not fractionated, thus reducing costs.

Table 6

TABLE 6 Moisture Oil Split (wt. %) Grain 11%  9.6% Rotex  16.9% 20%retained HOF 17.16% 31% LOF  2.5% 49%

EXAMPLE 6

The HOF from Examples 2 through 5 was collected in a surge bin andmetered by a Buhler feeder DPSA (Buhler Group, address) to a Buhlerhomogenizer DPSD (Buhler GmbH, Germany) which added steam or water tothe HOF to condition the HOF. The conditioned HOF was then fed into aBuhler Condex Expander DFEA-220 (Buhler GmbH, Germany) fitted with a 30slot 8 mm die head to form shaped expanded HOF. The shaped, expanded HOFwas cut to desired lengths by the expander. Steam was sparged into theexpander barrel to give the desired plasticity to the shaped, expandedHOF. The shaped, expanded, cut lengths of HOF were cooled andsubsequently solvent extracted in a hexane extraction system, such asthat described in U.S. Pat. Nos. 6,388,110 and 6,313,328, incorporatedherein by reference. The parameters for operation of the conditioner,sparge steam rate, expander die pressure, and expander barrel pressurewere as follows:

Conditioner discharge temperature  25° C. Sparge steam to expanderbarrel 4% of feed rate to expander Expander die pressure 36 bar Expanderbarrel temperature 143° C.

Ninety three percent of the oil from the HOF was extractable inlaboratory extraction tests. Percolation and drainage were acceptable toone of ordinary skill in the art by conducting visual observation belowthe bed of the extractor. The draining liquid did not puddle and theintensity of the drainage was high.

EXAMPLE 7

The pieces of cracked corn material which did not pass through the Rotexscreen described in Example 4 were milled in a Fitzmill comminuter(Fitzpatrick Company, Elmhurst, Ill.) fitted with a ¼ inch screen. Theground material was mixed with the HOF material from the Buhler-L. Thiscombined milled cracked corn and HOF was then fed to the Buhler Condexexpander described in Example 5. Expandettes of acceptableextractability were formed. The extractability was measured as describedin Aguilera et al., “Laboratory and Pilot Solvent Extraction of ExtrudedHigh-Oil Corn”, JAOCS, 63(2):239-243 (1986). An acceptable level ofresidual oil is less than about 15% of the original oil.

EXAMPLE 8

The large size pieces of cracked corn material which did not passthrough the Rotex screen described in Example 4 are heated to 70° C. Theheated cracked corn material is then pressed into a 4 mm thick flake ina Roskamp (Waterloo, Iowa) model number 2862 flaking mill. The flakesare then added to the cooled, shaped expanded HOF of Example 5.

EXAMPLE 9

The expanded higher oil fraction (9) is subjected to a supercriticalcarbon dioxide extraction process to remove the oil from this stream.The CO₂ can be produced locally by an ethanol-fermentation process wherethe feedstock material for the fermentors is one or more of the loweroil fractions (LOF (4), (lower oil cracked fraction (34)). Duringethanol fermentation, for every one mole of ethanol produced, one moleof CO₂ is produced. Typically the CO₂ is vented to atmosphere and notreclaimed. In this example the CO₂ produced from the ethanolfermentation of the LOF (4) and/or lower oil cracked fraction (34) iscaptured and cleaned using a carbon filter to remove organic impurities.The CO₂ is then compressed and stored. The CO₂ can then be used undersupercritical conditions to extract oil from the expanded HOF (9).Excess CO₂ can then be vented to atmosphere or recompressed and storedafter the oil has been separated from the CO₂/oil mixture. With thissystem, the CO₂ used for extracting the oil is produced in one plantlocation thereby reducing transportation costs.

EXAMPLE 10

Dried Distiller's Grain with Solids (“DDGS”) is a common by-productproduced during dry grind ethanol fermentation. DDGS tends to be high infiber and protein and is a good feed source for the ruminant feedindustry. DDGS is high in non-digestible phosphorous, due mainly fromthe presence of phytate. As waste phosphorous from animal productionfacilities continues to be a major issue facing the animal feedindustry, ways to reduce the phosphorous loading to the environment arebeing investigated. DDGS is especially challenging in that the DDGScontains about 3 times the phosphorous levels as the starting cornmaterial it came from due to the typical dry grind ethanol process, forexample, as described in Davis, Chippewa Valley Ethanol Company, Benson,Minn. (62^(nd) Minnesota Nuturion Conference and Minnesota Corn GrowersAssociation Technical Symposium, Bloomington Minn., September, 2001).The dry grind ethanol process consists of utilizing whole kernel corn asthe raw material for ethanol fermentation. The whole grain is ground upand the starch portion converted to sugar and the sugars are thenfermented to produce ethanol and CO₂. The remaining material (e.g., oil,fiber, protein) is dried and the resulting meal is called DDGS. Sincethe initial phytate and phosphorous levels in the corn are not removedduring the ethanol fermentation process, these components areconcentrated in the remaining material, which is DDGS.

The LOF (4), and the lower oil cracked fraction (34) contain lesseramounts of the germ and fiber as compared to a whole corn kernel. Thegerm and fiber are where most phytate and phosphorous is located in thecorn grain. Utilizing the LOF (4) and/or the lower oil cracked fraction(34) as a feedstock for ethanol fermentation provides a low phosphorousDDGS.

EXAMPLE 11

This example details a comparison of two different feed rations: a firstfeed ration containing normal corn that has not been solvent extractedand a second feed ration containing extracted corn meal produced by thepresent invention. The feed ration containing extracted corn meal isused when lean pork meat is a desired end product. A hog finishing feedration comprising an extracted corn meal containing less than or about1.5 wt. % oil is prepared by providing the following ingredients in theamounts indicated in Table 7. The feed ration is generally produced byblending, mixing, and pelletting the ingredients to produce a feedproduct; however, one or more of these steps can be omitted in theprocess of preparing the feed ration. Table 7 shows a comparison ofswine feed rations made using normal corn (not high oil corn) andextracted corn meal obtained from high oil corn comprising 12 wt. % oil,9 wt. % protein, wherein the extracted corn meal has about 1.5 wt. % orless of oil (fat). Amounts are expressed on an “as is” or “as fed”moisture level.

Table 7

TABLE 7 Swine Finishing Feed Normal Corn Extracted Corn (%) Meal (%)Ingredients Corn 79.98 — Extracted corn meal — 83.55 (about 1.5% oil)Soybean meal 12.45 6.60 Meat & bone meal 6.59 7.22 Feather meal — — Fat0.10 1.50 Salt 0.40 0.70 Lysine 0.08 0.15 Methionine — — Premix 0.150.15 Nutrient Crude protein, % 15.44 15.78 ME, kcal/kg 3200 3200 Crudefiber, % 1.96 2.12 Calcium, % 0.85 0.85 Phosphorus, % 0.58 0.58 AminoAcids, % Arginine 0.96 0.93 Cyctine 0.28 0.29 Histidine 0.40 0.42Isoleucine 0.57 0.58 Leucine 1.39 1.49 Lysine 0.81 0.81 Methionine 0.260.34 Phenylalanine 0.70 0.72 Threonine 0.56 0.58 Tryptophan 0.14 0.14Tyrosine 0.47 0.48 Valine 0.72 0.75

In Table 7, absolute values for ingredient percentages are given,however, in practice, the ingredients may include using the inclusionrates shown in other tables herein.

EXAMPLE 12

The feed ration of this example is used to fulfill the high-energyrequirements of growing birds such as broilers. A poultry broilerfinishing feed ration comprising an extracted corn meal containing lessthan or about 4 wt. % oil (fat) is prepared by providing the followingingredients in the amounts indicated in Table 8. The feed ration isgenerally produced by blending, mixing, and pelletting the ingredientsto produce a feed product; however, one or more of these steps can beomitted in the process of preparing the feed ration.

Table 8 shows the comparison of poultry feed rations made using normalcorn (not high oil corn) and extracted corn meal obtained from high oilcorn comprising 12 wt. %-oil, 9 wt. % protein, wherein the extractedcorn meal has about 4 wt. % or less of oil (fat). Amounts are expressedon an “as is” or “as fed” moisture level and absolute values foringredient percentages are given, however, in practice, the ingredientsmay be included using the inclusion rates shown in other tables herein.

Table 8

TABLE 8 Growing Broiler Extracted Normal Corn (%) Corn Meal (%)Ingredients Normal corn 66.85 — Extracted corn meal — 70.86 (about 4%oil) Soybean meal 20.96 16.42 Meat & bone meal 5.00 5.00 Feather meal2.00 2.00 Fat 3.29 3.76 Salt 0.37 0.37 Added Lysine 0.13 0.19 AddedMethionine 0.15 0.09 Premix 0.10 0.10 Nutrient Crude protein, % 19.4819.52 ME, kcal/kg 3100 3100 Crude fiber, % 1.97 2.12 Calcium, % 0.940.94 Phosphorus, % 0.63 0.62 Amino Acids, % Arginine 1.27 1.23 Cyctine0.38 0.39 Histidine 0.47 0.48 Isoleucine 0.78 0.79 Leucine 1.68 1.74Lysine 1.06 1.06 Methionine 0.44 0.44 Phenylalanine 0.92 0.92 Threonine0.74 0.75 Tryptophan 0.19 0.20 Tyrosine 0.61 0.62 Valine 0.95 0.96

EXAMPLE 13

In this example, oil with an increased level of tocotrienol content overconventionally produced crude corn oil is described. Corn oil is solventextracted from a higher oil fraction. The corn oil is then analyzed fortocotrienol content. Generally, increasing the extraction temperatureresults in an increase in the tocotrienol content of the extracted cornoil. The actual minimum and maximum values for tocotrienol content willdepend upon the particular high oil corn used.

EXAMPLE 14

This example illustrates a feed ingredient comprised of a blend of acorn meal produced by a method of the present invention and anotherplant-based meal such as an oilseed meal. This blended material could bein the form of simply a loose aggregate mixture of both meal types or apelletted product. It is possible to produce both meals in proximity andblend them prior to shipment to a customer. An advantage of thisapproach is that varying protein and energy levels can be created in asingle meal. Additional ingredients are optionally added either at themeal blending stage or at a later time. For example, an energy-intensivestep in feed manufacturing involves grinding corn grain and blending itwith other ingredients at a feed mill. The present blended mealgenerally requires less energy to produce a finished feed product thandoes a conventional blended meal.

Table 9 shows nutrient profiles of soybean meal (SBM), extracted cornmeal (ECM), a blend of 20% SBM and 80% ECM (S20-C80), a blend of 10% SBMand 90% ECM (S10-C90), and nutrient requirements for poultry and swinediets. The poultry and swine nutrient requirements shown are inaccordance with National Research Council (NRC) guidelines. The ECM wasprepared according to a method of the present invention.

Table 9

TABLE 9 Nutrient Nutrient 20% SBM & Needs for 10% SBM & Needs forParameter SBM ECM 80% ECM Poultry Diets 90% ECM Swine Diets CrudeProtein (CP) 47.5 10.2 17.66 18 13.93 13.2 Swine ME, kcal/kg 3380 33013316.8 3308.90 3265 Poultry ME, kcal/kg 2440 3133 2994.4 3200 3063.70Crude Fat, % 3 4 3.8 3.90 Neutral Detergent Fiber, % 8.9 11.3 10.8211.06 Acid Detergent Fiber, % 5.4 2.8 3.32 3.06 Arginine 3.48 0.45 1.061.00 0.75 0.19 Histidine 1.28 0.27 0.47 0.27 0.37 0.19 Isoleucine 2.160.34 0.70 0.62 0.52 0.33 Leucine 3.66 1.03 1.56 0.93 1.29 0.54 Lysine3.02 0.33 0.87 0.85 0.60 0.60 Methionine 0.67 0.25 0.33 0.32 0.29 0.16Cystine 0.74 0.21 0.32 0.28 0.26 0.35 Phenylalanine 2.39 0.44 0.83 0.560.64 0.34 Tyrosine 1.82 0.29 0.60 0.48 0.44 0.55 Threonine 1.85 0.340.64 0.68 0.49 0.41 Tryptophan 0.65 0.09 0.20 0.16 0.15 0.11 Valine 2.270.45 0.81 0.70 0.63 0.40 Total Essential Amino 23.99 4.49 8.39 6.85 6.444.17 Acids (EAA) EAA/CP 0.505 0.440 0.45 0.381 0.45 0.316

EXAMPLE 15

The extracted oil is recovered and analyzed for vitamins, fatty acids,and micronutrients. As a control, 800 lbs. of yellow #2 corn isextracted in an identical manner, and the recovered oil was analyzed forthe same components. Vitamin A and β-carotene are analyzed by a contractlab using a proprietary procedure. Alternative published proceduresinclude Bates et al., Proc. Fla. State Hort Soc., 88:266-271 (1975).Free fatty acids are analyzed by gas chromatography (GC) using a CP88cyanopropyl column (100 m×0.265 mm, 0.5 mm film thickness) and a flameionization detector as described in American Oil Chemist Society (AOCS)methods Ce 1c-82, Ce 2-65, Cd 3a-94, and Cd 1c-85.

Tocopherols and tocotrienols are analyzed by high performance liquidchromatography (HPLC, Waters model number 2590) using a normal phasesilica column with hexane-isopropanol as the mobile phase and detectedusing fluorescence detection (Waters model number 2690), according tothe procedure described in AOCS Ce 8-89. Lutein is analyzed by HPLCusing a C30 reverse phase column with water-acetonitrile mobile phaseand detected with a UV detector.

Table 10 set forth below, presents a comparison of the expected oilcomposition to be obtained from high oil corn and yellow #2 corn. Forcomparison, the composition of oil from yellow #2 corn extracted in acorn wet milling process is also given.

Table 10

TABLE 10 High Oil Y#2, Corn Component Corn Yellow #2 wet MillingPalmitic Acid % 11.4 10.7 10.7 Stearic Acid % 2.2 1.9 2.0 Oleic Acid %35.6 25.5 27.5 Linoleic Acid % 48 58.4 57.1 Linolenic Acid % 0.7 1.2 1.1α-Tocotrienol (ppm) 184 48 12 α-Tocopherol (ppm) 237 231 136 Vitamin B1,mg/100 g 0.390 NA 0.260 Vitamin B2, mg/100 g 0.090 NA 0.080 Vitamin B6,mg/100 g 0.82 NA 0.4 Vitamin B12, mg/100 g 0.5 NA 0.5

EXAMPLE 1

This example sets forth a description of using the extracted corn mealof the present invention to produce biodegradable materials withimproved tensile strength.

Extracted corn meal of the present invention is suspended in hexanes ina sealed container, at a 2:3 corn meal:solvent weight ratio. The mixtureis allowed to stand at room temperature without mixing for about 18hours. The organic solvent is removed from the extracted corn meal, andthe extracted corn meal residue is washed during filtering with analiquot of hexanes in a 1:1 residue:solvent weight ratio. The residue isdried in a convection oven at 50° C. for 16 hours. The dried residue issprayed with water with mixing until the moisture content of the residueis 10.7% to 11.3%. The solvent-treated extracted corn meal compositionis molded into an ASTM standard dogbone article using a compressionmolding press (Wabash Metal Products, Inc. Wabash, Ind.) at 5000 psi,140° C. to 160° C. for 10 minutes. The untreated corn meal compositionis likewise combined with water to a 10.7% to 11.3% water content andmolded into an ASTM standard dogbone article. The articles produced withthe solvent-treated extracted corn meal produced by a method of thepresent invention will exhibit significantly improved tensile propertiesas compared to non-solvent treated extracted corn meal.

Alternatively, corn meal of the present invention is separatelysuspended in aqueous ethanol (95%) at 1:3 weight-ratio of meal to oil,and boiled for 2 hours with reflux and mechanical stirring. The meal isfiltered and the residues are washed with ethanol (1:1 residue:ethanol).The residues are dried, remoistened, and molded according to theprocedure above. Tensile properties and water-absorption of the mealtreated with ethanol at boiling temperature for a short 2 hour periodwould be similar to the meals treated at room temperature for anextended 18 hour period.

EXAMPLE 17

This example sets forth the use of oil from high oil corn as a source ofa biodiesel fuel.

In a continuous process, approximately 62 kg/hr (137 lbs/hr) of oilextracted from a higher oil fraction produced by the present inventionand refined according to known industry processes, is mixed with 18kg/hr (40 lbs/hr) of methanol in a stirred tank reaction unit.Simultaneously 0.08 kg/hr (0.1775 lbs/hr) of sodium hydroxide is addedto the same stirred tank reaction unit, which operates at 20 psig andapproximately 80° C. These conditions provide essentially 100%conversion of added triglycerides to fatty acids and methyl esters. Thetwo phases of the reaction mixture are allowed to stand and separate toprovide methyl esters in the upper phase, and a mixture of glycerol andapproximately 10-15 wt. % residual methyl esters, methanol, and base inthe lower phase. Approximately 6.4 kg/hr (14 lbs/hr) of the glycerolphase is neutralized, present methanol flashed off, and the remainder issent to a continuously stirred reaction unit, operated at 80° C. and 320psig. The reaction unit also contains approximately 4 wt. % Amberlyst-15catalyst with a residence time of 2 hours and approximately 7.9 kg/hr(17.5 lbs/hr) iso-butylene is fed to the reaction unit. The biodieselfuel is produced at approximately 66 kg/hr (145 lbs/hr) and has akinematic viscosity and cloud-point that is greater than biodieselwithout glycerol ethers present.

EXAMPLE 18 (A) Starch Hydrolysis

Solvent extracted corn meal of the present invention prepared asdescribed herein is a rich source of starch for fermentation. The loweroil fraction of the present invention, or such lower oil fraction incombination with the extracted corn meal of the present invention canalso be used as a source of starch for fermentation. One method toprovide soluble sugars suitable for fermentation is to hydrolyze starchmolecules. Several types of enzymes that can be used to convert starchinto simple sugars are amylase(s), proteases, cellulase(s) (e.g.,xylonase), esterase(s) (e.g., ferulase, acetylesterase), andligninase(s). These enzymes may be used alone or in combination.

Five samples (i.e., one sample of yellow dent corn grain, two samples ofhigh oil corn grain and two samples of extracted high oil corn mealproduced by a method of the present invention) are ground to passthrough a 1 mm screen using a Retsch Mill. High oil corn meal samplenumbers 1 and 2, as shown in Table 16, are obtained from POS Pilot PlantCorporation (Saskatoon, Saskatchewan, Canada). Three hundred grams (300g) of each sample is combined with 700 ml of water at 99° C.-100° C.comprising 0.5 ml α-amylase and placed in a sealed container. The pH ofeach mixture is adjusted to 5.9 with base. Each mixture is stirred for45 min and additional α-amylase enzyme is added.

After an additional 45 min of incubation, the pH of each mixture isadjusted to 4.5 with acid. One-half of one milliliter (0.5 ml)glucoamylase (Optimax 7525) and 0.5 g protease (Fungal Protease 5000)are added to the sample mixtures and incubated with both enzymes at 62°C. for 22-24 h. Throughout the procedure, the degree of starchhydrolysis is monitored by HPLC (Waters 2690 Separations module) usingan organic acid column (Aminex HPX-87H Ion Exclusion Column, 300 mm×7.8mm, Bio Rad). Total nitrogen content for each sample is determined byLeco 2000 CN. Free amino nitrogen (FAN) is determined by the AOAC method(15^(th) Ed., 1990, p. 735).

(B) Fermentation

Media for fermentations are normalized on a weight basis. Each samplecomprises forty-five grams (45 g) of enzyme-treated and solventextracted corn meal (resulting in starting dextrose concentrations of133-233 g/L). Each sample is added to a 125 ml flask. Yeast extract isadded at 1 g/L to ensure that nitrogen is not limiting. Cultures areinoculated with 10% inoculum from overnight yeast cultures (a typicalAltech ethanol yeast of Saccharomyces cerevisiae) and incubationsproceed for 42 h at 30° C. on a rotary shaker at 125 rpm. Dextroseconsumption and ethanol production are monitored by HPLC.

EXAMPLE 19

This example sets forth the use of solvent extracted corn meal from thecurrent invention as a rich source of starch for the fermentativeproduction of citric acid. The production of citric acid from de-fattedcorn meal involves several steps including starch hydrolysis,fermentation, and citric acid recovery.

(A) Starch Hydrolysis

Solvent extracted corn meal and the lower oil fraction of the presentinvention prepared as described herein is a rich source of starch forfermentation. One method to provide soluble sugars suitable forfermentation is to hydrolyze starch molecules. Types of enzymes that canbe useful to convert the starch and protein matrix of corn meal intosimple sugars suitable for fermentation include amylase(s), proteases,cellulase(s) (e.g., xylonase), esterase(s) (e.g., ferulase,acetylesterase), and ligninase(s). Six samples (i.e., one sample ofyellow dent corn grain, one sample of yellow dent corn meal, two samplesof high oil corn grain and two samples of extracted high oil corn meal)are ground to pass through a 1 mm screen using a Retsch Mill. Threehundred grams (300 g) of each sample are combined with 700 ml of waterat 99° C.-100° C. comprising 0.5 ml α-amylase and placed in a sealedcontainer. The pH of each mixture is adjusted to 5.9 with base. Eachmixture is stirred for 45 min and additional α-amylase enzyme is added.

After an additional 45 min of incubation, the pH of each mixture isadjusted to 4.5 with acid. One-half of one milliliter (0.5 ml)glucoamylase (Optimax 7525) and 0.5 g protease (Fungal Protease 5000)are added to the sample mixtures and incubated with both enzymes at 62°C. or 22-24 h. Throughout the procedure, the degree of starch hydrolysisis monitored by HPLC (Waters 2690 Separations module) using an organicacid column (Aminex HPX-87H Ion Exclusion Column, 300 mm×7.8 mm, BioRad). Total nitrogen content for each sample is determined by Leco 2000CN. Free amino nitrogen (FAN) is determined by the AOAC method (15^(th)Ed., 1990, p. 735).

(B) Fermentation and Citric Acid Production

Once the starch from solvent extracted corn meal is suitably preparedthrough treatment with enzymes, the solution is filtered anddemineralized according to commonly known practices. Resulting sugarsare brought to a solids content of about 120 mg/l with demineralizedwater in a deep-tank fermentation vessel. The deep tank method is alsoknown as the submerged process. In this method the tank is supplied withsterile air, nutrients and a carbon source, (hydrolyzed starch), andinoculated with Aspergillus niger spores. Spores of the fungus in aconcentration of about 100 spores per liter of culture liquid, whichcorresponds to an amount of 10 to 15 g of spores per cubic meter (m³)are added to the nutrient solution and the citric acid production iscarried out by the fungus. Examples of A. niger strains are ATCC 1015described in U.S. Pat. No. 2,492,667, and DSM 5484 described in U.S.Pat. No. 5,081,025.

The incubation of the broth thus inoculated is carried out at conditionsgenerally known and described for citric acid production, such ascontinued aeration and temperature control. During the fermentationprocess, the temperature is maintained at about 32° C. (90° F.), the pHis maintained at about 2 to 3 with sodium citrate, and sterile air isadded to maintain about 50% dissolved oxygen content. Fermentation iscarried out until the fermentation broth reaches a reducing sugarcontent of about 1 g/L, which may require several days to achieve. Twomain separation processes can be used in the recovery of citric acid,the Lime-Sulfuric Acid process and the Liquid extraction process. TheLime-Sulfuric Acid method is commonly used and is familiar to thoseskilled in the art of citric acid production.

EXAMPLE 20

This example describes the extraction of oil from yellow dent #2 corn(commodity field corn).

The HOF produced from Yellow dent #2 corn was expanded using a modelDFEA-220 expander (Buhler GmbH, Germany) to create collets. Moisture wasintroduced in the form of steam into the expander barrel. The rate ofsteam addition ranged from 6.0 to 6.8%. The expanded HOF was cooled in ahorizontal ambient air cooler that reduced the moisture content tobetween 10 and 13% moisture. The HOF was expanded to make it suitablefor presentation to a full-scale solvent extractor.

Two truckloads of the expanded HOF were metered into a full-scaleextraction process at an inclusion of 23-32% HOF. The balance was wetmilled germ expeller cake. The trucks were unloaded into the wet milledgerm flow over a 3.5 hr period. The combination was extracted in ashallow bed Crown Model III extractor. The extractor is sized for 1000T/day. Table 11 shows results of different sample points during thetrial:

Table 11

TABLE 11 Fat % Protein % Moisture % FFA % Extractor Feed 16.0-17.2 —4.96-7.06 2.0-3.4 Extractor Discharge 0.98-1.33 — 7.80-8.95 — DC/DTDischarge 2.77-4.92 19.02-20.21 10.99-12.18 — Finished Oil to Storage —— — 1.4-1.7 FFA = free fatty acids, DC = dryer/cooler DT = desolventizertoaster

Similarly, HOF is produced from yellow #2 corn. It is made into asolvent-extractable structure, solvent extracted and the extracted cornmeal is used as a feedstock for fermentation.

EXAMPLE 21

This example sets forth one embodiment of a combination of wet and drymilling techniques.

Dry milling corn provides a crude separation of the kernel components.It is typically used when high purity starch and other products are notnecessary. It is generally used to produce fermentation feedstock inethanol producing facilities, because the yeast does not need highpurity feedstock. Dry milling is less capital intensive and uses lessenergy than wet-milling. In contrast, wet-milling provides high puritystarch, protein, and oil. The use of a mechanical separation step, suchas a fractionation step, prior to using one or more wet-millingtechniques, allows for the production of high purity products withoutusing a process that is as energy and capital intensive as wet milling.

In the corn wet-milling process the soaking of the grain is termed“steeping.” The steeping process of corn, generally, includes theaddition of sulfur dioxide (from about 0.1 to about 0.3%) and steepingtimes of from about 24 to about 48 hours at temperatures between fromabout 45 to about 60° C. After steeping, light steep water is obtained,which contains a high percentage of the soluble parts from the cornkernels. The resulting steeped corn kernels are relatively softer thanthey were prior to steeping and at the end of the steeping process theycan be separated into germs, fiber, starch and proteins.

The steeped corn is coarse ground in a coarse grinding mill in two stepsto release the germ from the kernels. The germs are separated after eachcoarse milling step. Germs have an oil content of approximately 45-55%.The oil is usually extracted in subsequent refining steps.

The remaining coarse de-germed kernels are milled in a coarse grindingmill for the third time to disrupt the endosperm matrix and release thestarch. Fibers are removed from the starch and endosperm proteins bypassing the slurry over a series of screens.

The separated fiber is then dewatered and dried. In some instances thefiber is combined with steep water that has been concentrated inevaporators until it reaches about 45 to about 50% dry solids. The driedmixture of fiber and steepwater is referred to as corn gluten feed.

The remaining starch protein mixture is thickened and separated using aseries of centrifuges. In the mill-stream thickener (MST) centrifuge,the feed density is increased to improve separation of starch andendosperm protein (gluten). The overflow from the MST is sent to thesteep house for use as steep water. The underflow from the MST is sentto the primary centrifuge (primary separation step). In the primaryseparation step the gluten proteins are partially separated from thestarch. The overflow from the primary centrifugation step is the lightgluten stream. The primary underflow is sent to starch washing to purifythe starch. Overflow from the starch wash step is thickened in theclarifying centrifuge. The clarifier underflow is returned to theprimary centrifuge feed tank. The clarifier overflow is used for primarycentrifuge wash water and fiber wash water.

The light gluten stream, containing about 5% dry solids, is concentratedin the gluten thickener centrifuge. The overflow is used for fiber andgerm washing. The underflow, referred to as heavy gluten contains fromabout 10 to about 20% of dry substance, mainly insoluble proteins (about64% on dry base) and from about 10 to about 25% of starch (on dry base).The suspended solids in the heavy gluten are separated from the processwater with rotary vacuum filters. The gluten cake that discharges fromthe filters contains about 55 to about 65% water. The process water(sometimes referred to as gluten filtrate) that was separated from thegluten cake is returned to the gluten thickener feed tank. The glutencake is dried to a moisture content of about 10 to about 12%, and isreferred to as corn gluten meal. The HOF and the LOF generated in thefractionation step(s) shown in FIGS. 1 and 2 can be used in awet-milling process, however, they will be inputted into the wet-millingprocess at different points.

LOF has already had a significant amount of the germ removed in thefractionation step. Therefore, the LOF can be input into the wet-millingprocess during the steeping step (steeping can be either batch orcontinuous), but it is expected that the LOF will require a much shortersteep time, and less SO₂ and possibly eliminating the need for SO₂. Thesteep time can additionally be made shorter by incorporating the use ofultrasound, mixing, and the like into the process.

In another embodiment, the steeping process can be skipped by drygrinding the LOF and introducing the ground LOF into the third grind orfiber wash. In embodiments where the ground LOF is being integrated intoan existing running wet-mill, it is expected that the concentration ofthe SO₂ at the third grind will be sufficient to facilitate theseparation of the protein from the starch.

In some embodiments, it may be desirable to add organic acids tofacilitate the separation of the LOF. Organic acids that may be usefulfor this process included for example lactic acid, citric acid, and thelike.

The HOF, e.g. after expansion, is mixed, as in Example 20, with germrecovered from wet-milling and the products are combined prior toextraction.

One of ordinary skill in the art will appreciate that any product thatcan be made in a traditional wet-mill can be made by a mill thatincorporates the use of HOF or LOF into the process. For example, suchproducts include crude oil, fermentation feedstocks, high fructose cornsyrup, corn syrup, sweeteners, corn gluten feed, corn gluten meal,starch, extracted meal, animal feed, fertilizer, and the like.

EXAMPLE 22

This example compares the recovery of oil between using one and twostage fractionation.

Two batches of approximately 3 tons each of Mavera™ high value corn(Renessen S. R. L., Argentina) were fed to a Buhler-L apparatus, onebatch after tempering with 1.6% water and one batch without tempering,to form HOF and LOF. The larger pieces of LOF that were discharged fromthe Buhler-L were sifted across a 6000 micron screen MPAD Pansifter. Thematerial that went through the screen became small LOF. The materialthat was retained on the screen (retained LOF) was fed to a Buhler-Lapparatus for processing. The resulting second stage HOF from this stepwas added to the HOF from the first stage fractionation. Likewise, theLOF from the second stage fractionation step was combined with the smallLOF stream. By adding the second fractionation stage, the percentage ofthe recovered oil from the HOF fractions of the grain increased over asingle stage fractionation. Table 12 compares the results from 1 stagefractionation (no tempering), 2 stage fractionation (no tempering) and 2stage fractionation, tempering with 1.6% water.

Table 12

TABLE 12 % fat - % % fat - % Recovery LOF LOF/feed HOF HOF/feed of oil 1stage 3.4% 80% 17.8%   20% 56% (no tempering) 2 stages 1.4% 64% 16% 36%89% (no tempering) 2 stages- 1.0% 60% 14% 40% 87% tempering with 1.6%water

EXAMPLE 23

This example illustrates an increase in mill efficiency when producingpelleted feeds by using the a combined meal comprising solvent extractedHOF and LOF (The “Enhanced Meal) of the current invention.

Feed pellets formulated for a broiler diet were produced using EnhancedMeal, with increasing levels of added fat, and compared to pelletsformulated to the same diet using standard yellow #2 corn. For all dietsthe Enhanced Meal was substituted at an equal weight basis for theground yellow #2 corn. The formulations for the above treatments aredescribed in Table 13.

Table 13

TABLE 13 Treatment Enhanced Enhanced Enhanced Enhanced Meal Meal MealMeal Control 0% added 1.5% added 2.0% added 2.5% added INGREDIENT Y#2Corn fat fat fat fat Corn/Enhanced 65.00% 65.00% 65.00% 65.00% 65.00%Meal Soybean meal 31.50 31.50 31.50 31.50 31.50 Soybean oil 1.50 0.001.50 2.00 2.50 Limestone 1.34 1.34 1.34 1.34 1.34 Salt 0.28 0.28 0.280.28 0.28 DL-methionine 0.08 0.08 0.08 0.08 0.08 Poultry Premix** 0.250.25 0.25 0.25 0.25 **Premix contains supplement vitamins and traceminerals which meets or exceeds those required for normal growth inpoultry as outlined in National Research Council Poultry NRC, 1994

Additionally, pellets for companion animal and aquaculture feeds aregenerated using either Enhanced Meal or standard yellow #2 corn.Examples of these formulations are shown in Tables 14-15.

Table 14

TABLE 14 Ingredient % Yellow #2 corn/Enhanced Meal 17 Rice Bran 4.5Soybean Meal 32 Salt 0.5 Calcium Carbonate 0.74 Fish Meal 10 Mono-DicalPhosphate 2 DL-methionine 0.26 Fat 1.5 Wheat Middlings 25 Poultry Meal1.8 Feather Meal 4 Vitamin Premix** 0.3 Trace Mineral Premix** 0.4 Total100 **Premix contains supplement vitamins and trace minerals which meetsor exceeds those required for normal growth in poultry as outlined inNational Research Council Poultry NRC, 1994

Table 15

TABLE 15 Ingredient % Yellow #2 corn/Enhanced Meal 56.12 Wheat Middlings5 Meat and Bone Meal 15 Salt 0.5 Mono-dical 2.4 Corn Gluten Meal 9.1Choline CHL-60 0.08 Brewer's Rice 10 Vitamin Premix** 0.2 Trace MineralPremix** 0.1 Fat 1.5 TOTAL 100 **Premix contains supplement vitamins andtrace minerals which meets or exceeds those required for normal growthin poultry as outlined in National Research Council Poultry NRC, 1994

The Enhanced Meal was prepared by pelleting a combination of solventextracted HOF with LOF. was received in bulk as ¼ inch pellets, having aloose bulk density of 54 Kg/hl and 32% fines passing through a #14screen. The proximate analysis for this product is shown in Table 16.The results show that the Enhanced Meal was 2.0% lower in fat content ascompared to yellow #2 corn of an equivalent weight.

Table 16

TABLE 16 Ash, % 1.80 Moisture, % 11.51 Fat Acid Hydrolysis, % 3.21 EtherExtract Fat, % 1.55 Protein, % 8.68 ADF, % 2.43 NDF, % 9.73 Crude Fiber,% 2.00

The yellow #2 corn grain and Enhanced Meal were ground prior topelleting using a Jacobson model P-240, 30 hp hammermill, equipped withnew hammers and an 8/64″ screen. The results showed that at the samemotor load, the Enhanced Meal resulted in an increased throughput(lbs/hr) of 42% and a decrease in energy consumption (Kwh/T) of about30% per ton processed. These results indicate that there would be asignificant cost savings to the mill by using Enhanced Meal as comparedto yellow #2 corn.

Feed pellets comprising Enhanced Meal or yellow #2 corn grain weregenerated using methods well known in the art (see for example Gilpin etal., Applied Engineering in Agriculture 18(3): 331-338 (2002)). Thepellets were formed using a CPM Master HD model (California Pellet MillCompany, Crawfordsville, Ind.) pellet mill, which was equipped with a5/32″×1.25″ die. Conditioning temperature was held constant at 180° F.(80° C.). The feed screw rate was held constant at 8.8 revolutions perminute (rpm). A recording volt/amp meter was attached to the pellet milldrive motor and voltage and amp loads were recorded and averaged acrossthe treatment run.

The pellet quality was determined as described in Appendix E (pp.551-552) and Appendix F (p. 558), Feed Manufacturing Technology IV,American Feed Industry Association (1994). A modified, more rigorousversion of the aforementioned standard PDI test was done by includingfive ½″ hex nuts to the tumble chamber (modified PDI).

The results indicate that all pellet formulations, regardless of oilinclusion level, resulted in substantially improved pellet qualitycompared to the control. For example, results for the modified PDI testshowed values of greater than 90% for all of the Enhanced Mealtreatments as compared to 83% for the control of yellow #2 corn (Table17). Previous experiments had shown that pellets formed with equivalentlevels of oil, for example shell corn, had modified PDI ratings nogreater than 85%.

Table 17

TABLE 17 Enhanced Enhanced Enhanced Enhanced Meal Meal Meal Control Meal0% 1.5% 2.0% 2.5% (Y#2) added Fat added Fat added Fat added Fat StandardPDI 87.55 97.40 95.44 94.72 92.88 Modified PDI 83.26 96.80 94.52 93.3090.80

The results in terms of production rate (lb/hr) indicate that there wereno statistical differences among treatments (Table 18). There was,however, a substantial difference in the relative energy usage (Kwh/T)between the Enhanced Meal with no added fat and all other diets (Table19). This result was expected as the lack of a lubricating effect fromthe low oil content of the Enhanced Meal would result in increasedfriction in the die and rolls.

The results of these studies indicate that the Enhanced Meal with 2.5%added fat level would be the best formulation for broiler feed pelletsin terms of production rate, energy usage and pellet quality. Similarresults are seen with aquaculture and companion animal feeds.

Table 18

TABLE 18 Treatment Control (Y#2 corn) Enhanced Meal lbs/hr 3760 5326T/hr 1.88 2.66 Kwh/T 4.90 3.41 T/Kwh 408 586 Particle size (microns) 606638 Particle (standard deviation) 2.12 2.08

Table 19

TABLE 19 Treatment Enhanced Enhanced Enhanced Meal Meal Enhanced Meal 0%1.5% 2.0% Meal 2.5% Response #2 YC added Fat added Fat added Fat addedFat Production 1889.59 1848.42 1853.93 1823.33 1890.16 Rate (lb/hr)Kwh/T 11.3 13.0 11.8 11.83 11.37 Density 52.2 55.4 54.9 53.09 52.31(Kg/hL)

Unless otherwise defined, all technical and scientific terms andabbreviations used herein have the same meaning as commonly understoodby one of ordinary skill in the art to which this invention pertains.Although methods and materials similar or equivalent to those describedherein can be used in the practice of the present invention, suitablemethods and materials are described below without intending that anysuch methods and materials limit the invention described herein. Allpatents publications and official analytical methods referred to hereinare incorporated by reference in their entirety. Additional features andadvantages of the present invention will be apparent from the followingdescription of illustrative embodiments of the present invention andfrom the claims.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. Recitation of ranges of values herein are merely intended toserve as a shorthand method of referring individually to each separatevalue falling within the range, unless otherwise indicated herein, andeach separate value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., “such as”) provided herein, isintended merely to better illuminate the invention and does not pose alimitation on the scope of the invention unless otherwise claimed. Nolanguage in the specification should be construed as indicating anynon-claimed element as essential to the practice of the presentinvention.

Preferred embodiments of the present invention are described herein,including the best mode known to the inventors for carrying out thepresent invention. Of course, variations of those preferred embodimentswill become apparent to those of ordinary skill in the art upon readingthe foregoing description. The inventors expect skilled artisans toemploy such variations as appropriate, and the inventors intend for thepresent invention to be practiced otherwise than as specificallydescribed herein. Accordingly, the present invention includes allmodifications and equivalents of the subject matter recited in theclaims appended hereto as permitted by applicable law. Moreover, anycombination of the above-described elements in all possible variationsthereof is encompassed by the present invention unless otherwiseindicated herein or otherwise clearly contradicted by context.

1. A method of dividing a whole corn kernel of high oil corn comprising:fractionating a whole corn kernel of high oil corn having a range ofmoisture from about 8 wt. % to about 22 wt. %, and further having anendosperm component and a germ component, into a higher oil fraction anda lower oil fraction, wherein, the higher oil fraction has an oilconcentration greater than that of the corn kernel and the lower oilfraction has an oil concentration less than that of the corn kernel. 2.The method of claim 1, wherein fractionating comprises contacting thewhole corn kernel with an abrasive screen to separate at least a portionof the germ component of the corn kernel from at least a portion of theremainder of the corn kernel.
 3. The method of claim 2, whereinfractionating comprises subjecting the whole corn kernel to a Buhler Lmachine, a Satake debranner, or other means for contacting the cornkernel with a device to remove at least a portion of the germ componentof the corn kernel from at least a portion of the remainder of the cornkernel.
 4. The method of claim 1, further comprising separating thelower oil fraction into larger and smaller pieces of lower oil fractionand fractionating the larger pieces of the lower oil fraction into asecond stage higher oil fraction and a second stage lower oil fraction;and, optionally, combining the second stage higher oil fraction and thehigher oil fraction; and, optionally, combining the second stage loweroil fraction and the lower oil fraction.
 5. A method of dividing a wholecorn kernel of high oil corn comprising: a) cracking into at least twodiffering sized pieces of cracked corn, a whole corn kernel of high oilcorn having a range of moisture from about 8 wt. % to about 22 wt. %,and further having an endosperm component and a germ component; and,optionally, further separating a portion of the cracked corn pieces intoat least two fractions according to their size; and b) fractionating thecracked corn or optionally separated larger pieces of cracked corn intoa higher oil fraction and a lower oil fraction, wherein, the higher oilfraction has an oil concentration greater than that of the corn kerneland the lower oil fraction has an oil concentration less than that ofthe corn kernel.
 6. The method of claim 5, further comprising separatingthe lower oil fraction into larger and smaller cracked pieces of loweroil fraction and fractionating the larger pieces of the cracked loweroil fraction into a second stage cracked higher oil fraction and asecond stage cracked lower oil fraction; and optionally, combining thesecond stage cracked higher oil fraction and the higher oil fraction;and, optionally, combining the second stage cracked lower oil fractionand the lower oil fraction.
 7. The method of claim 1, further comprisingtempering the corn kernel at a temperature and for a time sufficient toincrease the differential hardness between the germ component and theremainder of the corn kernel.
 8. The method of claim 5, furthercomprising tempering the cracked corn pieces at a temperature and for atime sufficient to increase the differential hardness between the germcomponent and the remainder of the cracked corn pieces.
 9. The method ofclaim 1, further comprising extracting oil from a portion of the higheroil fraction, the second stage higher oil fraction, the cracked higheroil fraction, or the larger pieces of the cracked pieces of the secondstage oil fraction to produce an extracted corn oil and an extractedcorn meal.
 10. The method of claim 9, further comprising forming aportion of the higher oil fraction, the second stage higher oilfraction, the cracked higher oil fraction, or the larger pieces of thecracked pieces of the second stage oil fraction into asolvent-extractable structure.
 11. The method of claim 10, whereinforming comprises one or more of extruding, expanding, expelling,pelleting or enzymatic treatment.
 12. The method of claim 11, furthercomprising solvent extraction of oil from a portion of thesolvent-extractable structure to produce an extracted corn oil and anextracted corn meal.
 13. The method of claim 11, further comprisingdesolventizing a portion of the extracted corn meal or extracted cornoil.
 14. The method of claim 5, further comprising aspirating a portionof the smaller size pieces of cracked corn to remove bran.
 15. Themethod of claim 5, comprising flaking a portion of the larger sizepieces of cracked corn to produce flaked, cracked corn.
 16. The methodof claim 5, further comprising grinding a portion of the larger sizepieces of cracked corn to produce ground, cracked corn.
 17. The methodof claim 15, further comprising solvent extraction of oil from a portionof the flaked, cracked corn material to produce an extracted corn oiland an extracted corn meal.
 18. The method of claim 16, furthercomprising solvent extraction of oil from a portion of the ground,cracked corn material to produce an extracted corn oil and an extractedcorn meal.
 19. The method of claim 16, further comprising forming aportion of the ground cracked corn material into a solvent-extractablestructure.
 20. The method of claim 16, further comprising combining aportion of the ground cracked corn and a portion of the higher oilfraction form a first combination material, and, optionally, forming aportion of the first combination material into a solvent extractablestructure.
 21. The method of claim 19, wherein forming into a solventextractable structure comprises one or more of extruding, expanding,expelling, pelleting, or enzymatic treatment.
 22. The method of claim21, further comprising solvent extraction of oil from a portion of thesolvent-extractable structure of the first combination material toproduce an extracted corn oil and an extracted corn meal.
 23. The methodof claim 20, comprising flaking a portion of the larger size pieces ofcracked corn to product flaked, cracked corn and further comprisingcombining a portion of the first combination material with a portion ofthe flaked, cracked corn material produced by the method of claim 15, toform a second combination material.
 24. The method of claim 23, furthercomprising solvent extraction of oil from a portion of the secondcombination material to produce an extracted corn oil and an extractedcorn meal.
 25. The method of claim 15, further comprising combining aportion of the flaked, cracked corn and a portion of the higher oilfraction.
 26. The method of claim 25, further comprising solventextraction of oil from the third combination material to produce anextracted corn oil and an extracted corn meal.
 27. The method of claim9, further comprising desolventizing a portion of the extracted cornmeal.
 28. The method of claim 1, further comprising using a portion ofthe lower oil fraction as a feedstock for fermentation, wet cornmilling, food pet food or other process.
 29. The method of claim 27,further comprising using a portion of the desolventized, extracted mealas a feedstock for fermentation, wet corn milling, food, pet food, orother process.
 30. The method of claim 12, wherein the solvent comprisescarbon dioxide from a fermentation process.
 31. The method of claim 1,further comprising using a portion of the higher oil fraction as afeedstock for fermentation, food, pet food, or other process.
 32. Themethod of claim 14, further comprising using a portion of removed branas a feedstock for extraction.
 33. The method of claim 32, furthercomprising extracting a portion of phytosterols from the bran feedstock.34. (canceled)
 35. A method of dividing a corn kernel comprising:fractionating at least one corn kernel having a range of moisture fromabout 8 wt. % to about 22 wt. %, and further having an endospermcomponent and a germ component, into a higher oil fraction and a loweroil fraction, wherein the lower oil fraction has an oil concentrationless than that of the corn kernel and the higher oil fraction has an oilconcentration greater than that of the corn kernel, and wherein lessthan 50% of the germ in the higher oil fraction is intact.
 36. Themethod of claim 35, further comprising using at least a portion of thelower oil fraction for one or more processes selected from the groupconsisting of fermentation, wet-milling, animal feed production,sweetener production, and starch production.
 37. The method of claim 35,further comprising using at least a portion of the higher oil fractionfor one or more processes selected from the group consisting of;fermentation, oil production, wet-milling, animal feed production,sweetener production, and starch production.
 38. The method according toclaim 35, wherein the fractionating is accomplished using a mechanicaldebranning machine.
 39. The method according to claim 35, furthercomprising forming a portion of the higher oil fraction into asolvent-extractable structure.
 40. The method of claim 39, whereinforming comprises one or more of extruding, expanding, expelling,pelleting or enzymatic treatment.
 41. The method of claim 40, furthercomprising solvent extraction of oil from a portion of thesolvent-extractable structure to produce an extracted corn oil and anextracted corn meal.
 42. The method of claim 41, further comprisingfermenting a portion of the extracted corn meal.
 43. An extracted mealproduct produced by the method of claim
 1. 44. A lower or higher oilfraction produced by the method of claim
 1. 45. A solvent extractablestructure produced by the method of claim
 1. 46. The first combinationmaterial of claim
 20. 47. The second combination material of claim 23.48. The third combination material of claim
 25. 49. The aspirated branof claim
 14. 50. The extracted corn oil. produced by the method ofclaim
 1. 51. The desolventized extracted meal. produced by the method ofclaim
 1. 52. The desolventized extracted corn oil. produced by themethod of claim
 1. 53. A human food or animal feed comprising anextracted meal, extracted oil, or lower oil fraction. produced by themethod of claim
 1. 54. A biodiesel comprising the extracted corn oil.produced by the method of claim
 1. 55. A fermentation-based productproduced from a product selected from the group consisting of anextracted meal product, a lower oil fraction, and a higher oil fraction,wherein said product is produced by the method of claim
 1. 56. Theanimal feed of claim 53, wherein the animal feed is a swine feed,poultry feed, poultry layer feed, cattle feed, equine feed, dairycattle, aquaculture feed, or pet feed.
 57. The animal feed of claim 53,wherein the animal feed has been pelleted to form a pelleted meal.
 58. Acorn oil-containing product comprising the corn oil produced by themethod of claim 1, wherein the corn oil comprises: oil extracted from atleast the germ and endosperm of the corn; and at least one othercomponent extracted from one or more of the endosperm, tip cap orpericarp of the corn.
 59. The corn oil-containing product of claim 58,wherein the corn oil comprises: oil extracted from the germ and theendosperm of the corn; and at least one component selected from one ormore of the endosperm, tip cap or pericarp of the corn, wherein thecomponent is selected from the group consisting of a carotene, pigment,tocotrienol, tocopherol, antioxidant, fat soluble vitamin and sterol.60. The corn oil-containing product of claim 58, further comprising oneor more materials selected from the group consisting of conventionalcorn oil, soy oil, canola oil, olive oil, palm oil, sunflower oil,safflower oil, antioxidant, flavoring, hydrogenated oil, partiallyhydrogenated oil, and animal fat.
 61. The method of claim 9, wherein themethod further comprises the step of including the corn oil in a rawmaterial stream of an oil refining process.
 62. The method of claim 9,further comprising refining the corn oil.
 63. A biodegradable productmade from a material selected from the group consisting of extractedcorn meal, the lower oil fraction and a combination of extracted cornmean and lower oil fraction, wherein said material is produced by themethod of claim
 1. 64. The biodegradable product of claim 63, whereinthe extracted corn meal is treated with an organic solvent.
 65. Thebiodegradable product of claim 64, wherein the extracted corn meal isfurther treated with a cross-linking agent.
 66. A paper productcomprising a material selected from the group consisting of theextracted corn meal claim 1, the lower oil fraction, and a combinationof extracted corn meal and lower oil fraction, wherein said material isproduced by the method of claim
 1. 67. A method for producingfermentation-based products comprising: a) combining an enzyme, water,and a material selected from the group consisting of the extracted cornmeal, the lower oil fraction and a combination of extracted corn mealand lower oil fraction, wherein said material is produced by the methodof claim
 1. b) incubating the combination; and c) mixing the combinationwith a micro-organism capable of fermenting a carbon source to produce afermentation-based product.
 68. The method of claim 11, wherein theextraction is accomplished by extracting corn oil using a continuoussolvent extraction process.
 69. A method of forming an extracted blendedmeal comprising an extracted meal obtained from corn and one or moreextracted other oilseed meals, the method comprising: a) combining anextracted meal with one or more extracted other oilseed meals to form ablended meal, wherein the extracted meal has been prepared byfractionating a corn material into a higher oil fraction and a lower oilfraction, b) separating at least a portion of the higher oil fractionfrom the lower oil fraction, c) forming the higher oil fraction into asolvent extractable structure, and d) extracting the oil to produce theextracted meal.
 70. The method of claim 69, further comprising addingthe lower oil fraction to the extracted meal or the extracted blendedmeal.
 71. A method according to claim 69, wherein the one or more otheroilseed is selected from the group consisting of soybean, canola seed,sunflower seed, oilseed rape, and cotton seed.
 72. The method of claim5, further comprising extracting oil from a portion of the higher oilfraction, the second stage higher oil fraction, the cracked higher oilfraction, or the larger pieces of the cracked pieces of the second stageoil fraction to produce an extracted corn oil and an extracted cornmeal.
 73. The method of claim 72, further comprising forming a portionof the higher oil fraction, the second stage higher oil fraction, thecracked higher oil fraction, or the larger pieces of the cracked piecesof the second stage oil fraction into a solvent-extractable structure.74. The method of claim 73, wherein forming comprises one or more ofextruding, expanding, expelling, pelleting or enzymatic treatment. 75.The method of claim 74, further comprising solvent extraction of oilfrom a portion of the solvent-extractable structure to produce anextracted corn oil and an extracted corn meal.
 76. The method of claim74, further comprising desolventizing a portion of the extracted cornmeal or extracted corn oil.
 77. The method of any one of claim 5,further comprising using a portion of the lower oil fraction as afeedstock for fermentation, wet corn milling, food pet food or otherprocess.
 78. The method of claim 75, wherein the solvent comprisescarbon dioxide from a fermentation process.
 79. The method of any ofclaim 5, further comprising using a portion of the higher oil fractionas a feedstock for fermentation, food, pet food, or other process. 80.An extracted meal product produced by the method of claim
 5. 81. Anextracted meal product produced by the method of claim
 35. 82. A loweror higher oil fraction produced by the method of claim
 5. 83. A lower orhigher oil fraction produced by the method of claim
 35. 84. A solventextractable structure produced by the method of claim
 5. 85. A solventextractable structure produced by the method of claim
 35. 86. Theextracted corn oil produced by the method of claim
 5. 87. The extractedcorn oil produced by the method of claim
 35. 88. The desolventizedextracted meal produced by the method of claim
 5. 89. The desolventizedextracted meal produced by the method of claim
 35. 90. A human food oranimal feed comprising an extracted meal, extracted oil, or lower oilfraction produced by the method of claim
 5. 91. A human food or animalfeed comprising an extracted meal, extracted oil, or lower oil fractionproduced by the method of claim
 35. 92. A biodiesel comprising theextracted corn oil produced by the method of claim
 5. 93. A biodieselcomprising the extracted corn oil produced by the method of claim 35.94. A fermentation-based product produced from a material selected fromthe group consisting of an extracted meal product, a lower oil fraction,and a higher oil fraction, wherein said material is produced by themethod of claim
 5. 95. A fermentation-based product produced from amaterial selected from the group consisting of an extracted mealproduct, a lower oil fraction, and a higher oil fraction, wherein saidmaterial is produced by the method of claim
 35. 96. The animal feed ofclaim 90, wherein the animal feed is a swine feed, poultry feed, poultrylayer feed, cattle feed, equine feed, dairy cattle, aquaculture feed, orpet feed.
 97. The animal feed of claim 91, wherein the animal feed is aswine feed, poultry feed, poultry layer feed, cattle feed, equine feed,dairy cattle, aquaculture feed, or pet feed.
 98. The animal feed ofclaim 90, wherein the animal feed has been pelleted to form a pelletedmeal.
 99. The animal feed of claim 91, wherein the animal feed has beenpelleted to form a pelleted meal.
 100. A method of improving pelletquality or improving efficiency of producing pelleted animal feedscomprising substituting the pelleted meal of claim 57 for yellow #2corn.
 101. A method of improving pellet quality or improving efficiencyof producing pelleted animal feeds comprising substituting the pelletedmeal of claim 100 for yellow #2 corn.
 102. A method of improving pelletquality or improving efficiency of producing pelleted animal feedscomprising substituting the pelleted meal of claim 101 for yellow #2corn.
 103. A corn oil-containing product comprising the corn oilproduced by the method of claim 5, wherein the corn oil comprises: oilextracted from at least the germ and endosperm of the corn; and at leastone other component extracted from one or more of the endosperm, tip capor pericarp of the corn.
 104. A corn oil-containing product comprisingthe corn oil produced by the method of claim 35, wherein the corn oilcomprises: oil extracted from at least the germ and endosperm of thecorn; and at least one other component extracted from one or more of theendosperm, tip cap or pericarp of the corn.
 105. The corn oil-containingproduct of claim 103, wherein the corn oil comprises: oil extracted fromthe germ and the endosperm of the corn; and at least one componentselected from one or more of the endosperm, tip cap or pericarp of thecorn, wherein the component is selected from the group consisting of acarotene, pigment, tocotrienol, tocopherol, antioxidant, fat solublevitamin and sterol.
 106. The corn oil-containing product of claim 104,wherein the corn oil comprises: oil extracted from the germ and theendosperm of the corn; and at least one component selected from one ormore of the endosperm, tip cap or pericarp of the corn, wherein thecomponent is selected from the group consisting of a carotene, pigment,tocotrienol, tocopherol, antioxidant, fat soluble vitamin and sterol.107. The corn oil-containing product of claim 105, further comprisingone or more materials selected from the group consisting of conventionalcorn oil, soy oil, canola oil, olive oil, palm oil, sunflower oil,safflower oil, antioxidant, flavoring, hydrogenated oil, partiallyhydrogenated oil, and animal fat.
 108. The corn oil-containing productof claim 106, further comprising one or more materials selected from thegroup consisting of conventional corn oil, soy oil, canola oil, oliveoil, palm oil, sunflower oil, safflower oil, antioxidant, flavoring,hydrogenated oil, partially hydrogenated oil, and animal fat.
 109. Abiodegradable product made from a material selected from the groupconsisting of the extracted corn meal, the lower oil fraction, and acombination of extracted corn mean and lower oil fraction, wherein saidmaterial is produced by the method of claim
 5. 110. A biodegradableproduct made from a material selected from the group consisting of theextracted corn meal, the lower oil fraction, and a combination ofextracted corn mean and lower oil fraction, wherein said material isproduced by the method of claim
 35. 111. The biodegradable product ofclaim 109, wherein the extracted corn meal is treated with an organicsolvent.
 112. The biodegradable product of claim 110, wherein theextracted corn meal is treated with an organic solvent.
 113. Thebiodegradable product of claim 111, wherein the extracted corn meal isfurther treated with a cross-linking agent.
 114. The biodegradableproduct of claim 112, wherein the extracted corn meal is further treatedwith a cross-linking agent.
 115. A paper product comprising a materialselected from the group consisting of the extracted corn meal, the loweroil fraction, and a combination of extracted corn meal and lower oilfraction, wherein said material is produced by the method of claim 5.116. A paper product comprising a material selected from the groupconsisting of the extracted corn meal, the lower oil fraction, and acombination of extracted corn meal and lower oil fraction, wherein saidmaterial is produced by the method of claim 35.